3. FRAME/BODY PANELS/EXHAUST SYSTEM

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Esmond Kelley
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1 3. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION 3-2 TROUBLESHOOTING 3-2 SEAT 3-3 MUD GUARD/FOOTPEG 3-3 TOP COVER ('04 - '05) 3-5 TOP COVER (After '05) 3-5 FRONT FENDER ('04 - '05) 3-6 FRONT FENDER (After '05) 3-6 REAR FENDER (After '05) 3-7 ENGINE GUARD ('04 - '05) 3-8 ENGINE GUARD (After '05) 3-8 SKID PLATE 3-8 FUEL TANK 3-9 HEAT GUARD PLATE ('04 - '05) 3-9 HEAT GUARD PLATE (After '05) 3-9 EXHAUST SYSTEM 3-10 REAR FENDER ('04 - '05)

2 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL This section covers removal and installation of the body panels, fuel tank and exhaust system. Always replace the gaskets after removing the exhaust system. Always inspect the exhaust system for leaks after installation. TORQUE VALUES Footpeg bracket bolt 42 N-m (4.3 kgfm, 31 Ibf-ft) Skid plate bolt 30 N-m (3.1 kgfm, 22 Ibf-ft) ALOC bolt: replace with a new one. Muffler mounting nut 32 N-m (3.3 kgfm, 24 Ibf-ft) Exhaust pipe band bolt 23 N-m (2.3 kgfm, 17 Ibf-ft) TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 3-2

3 SEAT REMOVAL Unlock the seat by pulling the release lever up. Pull the seat back and remove it. INSTALLATION Install the seat by inserting the groove under the retainer, and the prongs under the mounting rubbers. Push the seat forward and align the mounting bosses with the rubber mounts, then press down to lock it. FRAME/BODY PANELS/EXHAUST SYSTEM SEAT PRONGS GROOVE RUBBER MOUNTS RETAINER MOUNTING RUBBERS MUD GUARD/FOOTPEG REMOVAL After '05: Remove the brake light switch wire band from the right mud guard stay. Remove the following: - trim clip - washer-bolt - flange bolts - mud guard FLANGE BOLTS WASHER-BOLT 3-3

4 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the two bolts and footpeg. INSTALLATION Install the footpeg and tighten the two bolts. TORQUE: 42 Nm (4.3 kgfm, 31 Ibf ft) Install the following: - mud guard - new flange bolts - washer-bolt - trim clip TRIM CLIP FOOTPEG MUDGUARD When installing the washer-bolt for right side mud guard, align the mud guard stay with the groove in the frame as shown, then install and tighten the washer-bolt. FLANGE BOLTS FRAME WASHER-BOLT MUD GUARD STAY Align WASHER-BOLT After '05: Secure the brake light switch wire to the right mud guard stay with the wire band. 3-4

5 TOP COVER ('04 - '05) Remove the two bosses from the grommets and remove the top cover by releasing the four tabs. Install the top cover in the reverse order of removal. FRAME/BODY PANELS/EXHAUST SYSTEM TOP COVER BOSS TOP COVER (After '05) Remove the two bosses from the grommets and remove the top cover by releasing the six tabs. Install the top cover in the reverse order of removal. TABS GROMMET GROMMET TABSmtr 3-5

6 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER ( f 04 - f 05) Remove the following: - top cover (page 3-5) - two trim clips - three bolts and two collars - front fender by releasing the grommets from the bosses of the radiator grille. Install the front fender in the reverse order of removal. BOLTS FRONT FENDER (After '05) BOSSES Remove the following: - top cover (page 3-5) - trim clip - three bolts and two collars - front fender by releasing the bosses of the radiator grille. Install the front fender in the reverse order of removal. GROMMETS FRONT FENDER COLLARS TRIM CLIPS BOLTS FRONT FENDER 3-6

7 REAR FENDER ('04 - '05) Remove the seat (page 3-3). Release the three tabs from the grommets. Remove the two flange bolts, four washer-bolts, six collars and the rear fender. Install the rear fender in the reverse order of removal. FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER WASHER-BOLTS COLLARS FLANGE BOLTS REAR FENDER (After '05) Remove the seat (page 3-3). Unhook the heat guard rubber. Release the three tabs from the grommets. Remove the two flange bolts, four washer-bolts, six collars and the rear fender. Install the rear fender in the reverse order of removal. TABS HEATGUARD RUBBER WASHER-BOLTS COLLARS TAB FLANGE BOLTS REAR FENDER 3-7

FRAME/BODY PANELS/EXHAUST SYSTEM ENGINE GUARD ('04 - '05) Remove the two bolts and engine guard. Install the engine guard and tighten the two bolts securely.

8 FRAME/BODY PANELS/EXHAUST SYSTEM ENGINE GUARD ('04 - '05) Remove the two bolts and engine guard. Install the engine guard and tighten the two bolts securely. ENGINE GUARD (After '05) Release the water hose from the engine guard groove. Remove the two bolts and engine guard. Install the engine guard and tighten the two bolts and water hose securely. SKID PLATE Remove the six bolts, washers, collars and the skid plate. Install the skid plate with the six collars, washers and new bolts, and tighten the bolts. TORQUE: 30 N m (3.1 kgf m, 22 Ibf ft) BOLTS BOLTS, WASHERS, COLLARS 3-8

9 FUEL TANK Remove the following: - seat (page 3-3) - front fender '04 - '05: (page 3-6) After '05: (page 3-6) - rear fender '04-'05: (page 3-7) After '05: (page 3-7) - screw and fuel valve lever - fuel valve cover FRAME/BODY PANELS/EXHAUST SYSTEM FUEL VALVE LEVER SCREW FUEL VALVE COVER Disconnect the fuel hose from the fuel valve. Remove the holder bands, mounting bolts and the fuel tank. Install the fuel tank in the reverse order of removal. FUEL TANK HOLDER B A N D S HEAT GUARD PLATE ('04 - '05) Remove the throttle cable, hot start cable and main wire harness from the clamps of the heat guard plate. Remove the two trim clips and the heat guard plate by releasing the two tabs. Install the heat guard plate in the reverse order of removal. HEAT GUARD PLATE (After '05) Remove the throttle stop screw cable from the clamp of the heat guard plate. MOUNTING BOLTS si ^ ii H ^ HEATGUARD TABS PLATEWIRE HARNESS FUEL HOSE THROTTLE CABLE M^f %^c^:7 ' felpr \ TRIM CLIPS ir THROTTLE STOP SCREW CABLE /HOT START CABLE 3-9

10 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the wire band that secured the wire harness and alternator wire. ALTERNATER WIRE WIRE BAND TRX450R only: Disconnect the ignition coil primary wire, ground wire and ECT sensor wire. Remove the throttle cable and main wire harness from the clamps of the heat guard plate. Remove the hot start cable from the clamp of the heat guard plate. -i. \ A WIRE HARNESS j HOTSTART CABLE HEATGUARD PLATE Remove the three trim clips and the heat guard plate by releasing the two tabs. Install the heat guard plate in the reverse order of removal. ECTSENSOR WIRE EXHAUST SYSTEM REMOVAL Remove the two mounting nuts, bolts, washers and collars. IGNITION COIL PRIMARY AND GROUND WIRES MOUNTING NUTS, BOLTS '04-05: Loosen the two muffler band bolts, and remove the muffler and gasket. 3-10

11 After '05. Loosen the muffler band bolt, and remove the muffler and gasket. FRAME/BODY PANELS/EXHAUST SYSTEM Remove the two joint nuts, exhaust pipe and gasket. 3-11

12 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Loosely install the following: - new gasket - exhaust pipe - two joint nuts - new gasket - muffler - two collars, washers, mounting bolts and nuts '04-'05: MOUNTING BOLTS COLLARS SPARK ARRESTER MOUNTING NUTS GASKET EXHAUST PIPE JOINT NUTS MUFFLER After '05: WASHERS MOUNTING BOLTS COLLARS SPARK ARRESTER GASKET I EXHAUST PIPE MOUNTING NUTS _ JOINT NUTS MUFFLER ^ _ ^ GASKET ^ f Tighten the exhaust pipe joint nuts securely. 3-12

13 '04-05: Tighten the exhaust pipe band bolts. FRAME/BODY PANELS/EXHAUST SYSTEM TORQUE: 23 Nm (2.3 kgf-m, 17 Ibfft) After '05: Tighten the exhaust pipe band bolt. TORQUE: 23 Nm (2.3 kgfm, 17 Ibfft) Tighten the muffler mounting nuts. TORQUE: 32 Nm (3.3 kgfm, 24 Ibfft) MOUNTING NUTS, BOLTS 3-13

2. FRAME/BODY PANELS/EXHAUST SYSTEM

2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION.............. 2-2 NUMBER PLATE................... 2-5 TROUBLESHOOTING... 2-2 FRONT FENOER.................... 2-5 SEAT....................... 2-3