Page 1
2. EXHAUST MUFFLER/FRAME COVERS
2-0
PEO PL E 25 0
2
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EXHAUST MUFFLER/FRAME COVERS
__________________________________________________________________________________
SCHEMATIC DRAWING ---------------------------------------------- 2-1
SERVICE INFORMATION -------------------------------------------- 2-2
TROUBLESHOOTING ------------------------------------------------- 2-2
FRAME COVERS REMOVAL----------------------------------------- 2-3
EXHAUST MUFFLER REMOVAL ----------------------------------- 2-10
2
Page 2
2. EXHAUST MUFFLER/FRAME COVERS
2-1
PEO PL E 25 0
SCHEMATIC DRAWING
Page 3
2. EXHAUST MUFFLER/FRAME COVERS
2-2
PEO PL E 25 0
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use care not to pull them by force because the cover joint claws
may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler lock bolt 32_ 38N-m
Exhaust muffler joint lock nut 18_ 22N-m
TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Page 4
2. EXHAUST MUFFLER/FRAME COVERS
2-3
PEO PL E 25 0
FRAME COVERS REMOVAL
RIGHT AND LEFT BACK MIRROR
REMOVAL
Loosen the nut on the back mirror.
Remove the back mirror.
HANDLEBAR FRONT COVER
REMOVAL
Remove one bolt on the handlebar front
cover.
Remove the four screws attaching handlebar
rear cover to separate from handlebar rear
cover.
Disconnect all of the wire connectors,
couplers.
Remove handlebar front cover.
Nuts
Bolt
Screws
Wire Connectors
Page 5
2. EXHAUST MUFFLER/FRAME COVERS
2-4
PEO PL E 25 0
HANDLEBAR REAR COVER REMOVAL
Remove handlebar front cover. (!2-3)
Remove front cover. (
!2-4
)
Remove the bolt on the handlebar rear cover.
Remove the two screws attaching frame.
Disconnect all of the wire connectors,
couplers and the speedometer cable.
Remove the handlebar rear cover.
FRONT COVER REMOVAL
Remove the bolt on the front of the front
cover.
Remove the six screws attaching the leg
shield.
Screw
Screw
Blot
Handlebar Rear Cover
Screw
Wire Connectors
Wire Connectors
Speed Wire
Screws
Page 6
2. EXHAUST MUFFLER/FRAME COVERS
2-5
PEO PL E 25 0
Remove the four screws attaching the front
under cover. Disconnect the front cover from
leg shield and front under cover.
Disconnect all of the wire couplers.
Remove the front cover.
FRONT FENDER A/B REMOVAL
Remove the two screws that combine front
fender A with the front fender B.
Remove the two screws under the front
fender A.
Remover the front fender A.
Remover the bolt under front fender B that
combine front fender B with frame.
Remover the front fender B.
Wire Couplers
Screws
Bolts
Screws
Bolts
Bolt
Front Fender Cover A
Page 7
2. EXHAUST MUFFLER/FRAME COVERS
2-6
PEO PL E 25 0
RIGHT/LEFT SIDE COVER REMOVAL
Remove the screw combine right (left) side
cover with front under cover.
Remove the screw combine right (left) side
cover with the floor board.
Remove the right (left) side cover.
MET-IN BOX AND REAR CARRIER
REMOVAL
Open the seat with key.
Remove two bolts and two nuts on the met-in
box.
Disconnect all of the wire couplers.
Remove met-in box.
Remove three bolts and remove the rear
carrier.
BODY COVER/CENTER COVER/REAR
FENDER A REMOVAL
Remove six screws on air cleaner cover.
Loosen band to remove air cleaner cover and
disconnect air duct hose.
Screws
Band
Nuts
Bolts
Wire Couplers
Wire Couplers
Air Duct Hose
Screws
Page 8
2. EXHAUST MUFFLER/FRAME COVERS
2-7
PEO PL E 25 0
Remove the met-in box and rear carrier. (
!2-
6
)
Remove the four screws attaching the floor
board.
Remove the two screws on the rear fender A.
.
Disconnect all of the wire couplers.
Remove the body cover, center cover and rear
fender A together.
FLOOR BOARD REMOVAL
Remove the met-in box and rear carrier. (
!2-
6
)
Remove the body cover, center cover and rear
fender A together. (
!2-6
)
Remove right and left side cover. (
!2-6
)
Remove the four bolts on the floor board.
Remove the floor board.
Screws
Screws
Bolts
Wire Couplers
Screws
Page 9
2. EXHAUST MUFFLER/FRAME COVERS
2-8
PEO PL E 25 0
FRONT UNDER COVER REMOVAL
Remove the front cover. (
!2-8
)
Remove the right and left side cover. (
!2-6
)
Remove the two screws that combine the
front under cover with the leg shield.
Remove the front under cover.
LEG SHIELD REMOVAL
Remove the front cover. (
!2-4
)
Remove the side cover. (
!2-6
)
Remover the met-in box and carrier. (
!2-6
)
Remove the body cover, center cover and rear
fender A together. (
!2-6
)
Remove the floor board. (
!2-7
)
Remove the front under cover. (
!2-7
)
Remove the key molding and fuel tank cap
molding.
Remove the bolt on the leg shield.
Remove the screw on the frame that
combining the frame with the leg shield.
Remove the three screws that combine the
reserve water tank with the leg shield.
Remove the leg shield.
CENTER UNDER COVER REMOVAL
Remove the right and left side cover. (
!2-6
)
Remove the four bolts on the center under
cover.
Screw
Bolt
Screw
Key Molding
Fuel Tank Cap Molding
Screw
Screws
Bolts
Page 10
2. EXHAUST MUFFLER/FRAME COVERS
2-9
PEO PL E 25 0
Remove the center under cover.
REAR FENDER COVER B/C REMOVAL
Remove the met-in box. (
!2-6
)
Remove the body cover, center cover and rear
fender A together. (
!2-6
)
Remove the four screws on the rear fender B.
Remove the rear fender B.
Remove the two bolts on the rear fender C.
Bolts
Screws
Screws
Bolts
Under Cover
Rear Fender Cover B
Page 11
2. EXHAUST MUFFLER/FRAME COVERS
2-10
PEO PL E 25 0
Remove the screw attaching the air cleaner case.
Remove the rear fender C.
EXHAUST MUFFLER REMOVAL
Remove the two exhaust muffler joint lock
nuts.
Remove the three exhaust muffler lock bolts
to remove the exhaust muffler.
Remove the exhaust muffler joint packing
collar.
When installing, first install the exhaust
muffler packing collar onto the engine and
then install the exhaust muffler.
Torques:
Exhaust muffler lock bolt (next to exhaust
pipe): 32_ 38Nm
Exhaust muffler lock bolt: 59N-m
Exhaust muffler joint lock nut: 18_ 22N-
m
Screws
Joint Lock Nuts
Lock Bolts
Packing Collar
Rear Fender Cover C
Air Clean Case
Lock Bolts (next to exhaust pipe)
Be sure to install a new exhaust muffler
packing collar.
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