attaching the met-in box. Remove the met-in box. Remove the hand rail right ... Remove the six screws on the back of the front cover. Disconnect the right/left turn ...
SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6
2-0
2. EXHAUST MUFFLER/FRAME COVERS SCHEMATIC DRAWING
2-1
GRAND DINK 125/150
2. EXHAUST MUFFLER/FRAME COVERS
GRAND DINK 125/150
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.
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
2-2
2. EXHAUST MUFFLER/FRAME COVERS
GRAND DINK 125/150
Bolt
FRAME COVERS REMOVAL REAR CARRIER & HAND RAIL REMOVAL Remove the met-in box: First remove the three bolts and two nuts attaching the met-in box. Remove the met-in box.
Nuts Bolts
Remove the hand rail right and left lock hex bolts. Remove the two hex bolts Remove the rear carrier and hand rail.
Bolts Center Cover
FRAME BODY COVER REMOVAL Remove the two screws on the center cover. Remove the center cover.
Screws
Remove the three bolts on the back fender. Remove the back fender.
Bolts
2-3
2. EXHAUST MUFFLER/FRAME COVERS
GRAND DINK 125/150
Remove the two screws on the molding covers. Remove the molding covers.
Molding Cover
Screws
Remove the two nuts and one bolt on the back taillight.
Nuts
Blot Screws
Remove the left and right sides screws on the frame body cover. Remove the frame body cover.
FLOOR BOARD REMOVAL Remove the blot on the front right and left side covers.
Bolt
Side Cover
2-4
2. EXHAUST MUFFLER/FRAME COVERS Remove the left and right side screws on the side cover. Remove the side cover.
Remove the four bolts on the floor board. Remove the floor board.
GRAND DINK 125/150
Screws
Bolt
Bolts
Screws
FRONT UPPER COVER REMOVAL Remove the two screws on the front upper cover. Remove the front upper cover.
Remove the four bolts on the front windshield. Remove the front windshield.
2-5
Bolts
2. EXHAUST MUFFLER/FRAME COVERS
GRAND DINK 125/150
FRONT COVER REMOVAL First remove the front upper cover. Remove the two bolts attaching the front cover.
Bolts
Remove the six screws on the back of the front cover. Disconnect the right/left turn signal light wire connectors. Remove the front cover The installation sequence is the reverse of removal.
Screws
Remove the six screws on the front lower cover. Remove the front lower cover.
BACK COVER REMOVAL Remove the front cover. Remove the key moldings. Remove the fuel cap moldings. Remove the back cover bolt. Remove the back cover.
Screws
Key Moldings
Fuel Cap Moldings
Bolts
2-6
2. EXHAUST MUFFLER/FRAME COVERS Remove the three screws attaching fuel tank inlet tube join. Remove the back cover.
GRAND DINK 125/150
Screws
Fuel Tank Inlet Tube Bolts BOTTOM COVER REMOVAL Remove the side stand. Remove the four bolts attaching the bottom cover. Remove the bottom cover.
Side Stand
Bottom Cover FRONT FENDER REMOVAL Remove the two bolts attaching the fender. Remove the front fender cover. The installation sequence is the reverse of removal.
Bolts 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. The installation sequence is the reverse of removal. Torque: Exhaust muffler joint lock nut:11.8N-m Exhaust muffler lock bolt: 34.3N-m
2-7
Lock Bolts
2. EXHAUST MUFFLER/FRAME COVERS
GRAND DINK 125/150
HANDLEBAR COVER REMOVAL First remove the three screws attaching the handlebar under cover. Remove the handlebar under cover.
Screws Screw Remove the screw from the handlebar upper cover.
Remove the screw from the bottom of handlebar upper cover. Remove the handlebar upper cover.
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