13.2 Unscrew the downpipe nuts (arrowed)

1 Remove the drain and breather tubes from

the bracket on the back of the exhaust system below the engine unit (see illustration).

13.3A Unscrew the nut on the exhaust pipe mounting bolt...

2. Unscrew the nuts securing the downpipes to the cylinder head (see illustration).

3. Unscrew the nut and remove the washer and bolt securing the exhaust pipe to the frame bracket (see illustrations).

4. Unscrew the nut that secures the silencer to the frame and remove the washer, but leave the bolt in place (see illustration). Support the system, then withdraw the bolt and manoeuvre the downpipes away from the cylinder head.

5. Remove the gaskets from the exhaust ports and discard them as new ones must be used (see illustration).

6. If required, remove the clamp to separate the silencer from the exhaust pipe. Discard the joint gasket as a new one must be used.

13.3b ... and remove the bolt

13.4a Unscrew the silencer mounting nut...

13.4b ... and remove the exhaust system

4»14 Fuel and exhaust systems

13.5 Discard the old exhaust port gaskets

Installation

7 Installation is the reverse of removal, noting

the following:

a) Clean the jointing surfaces of the exhaust ports and the downpipes (see illustration). Smear the port gaskets with grease to hold them in place while fitting the exhaust system.

13.7a Clean carbon from the exhaust port jointing surface ...

2. Use new gaskets in each exhaust port and between the exhaust pipe and the silencer, if separated (see illustration).

3. Clean the cylinder head studs and lubricate them with a suitable copper-based grease before reassembly.

4. Check the condition of the rubber bushings on the exhaust pipe and silencer brackets and renew them if they are

13.7b ... and renew all gaskets where the system has been separated

damaged or deteriorated.

5. Leave all fasteners finger-tight until the entire system has been installed, making alignment easier. Tighten the mounting nuts and bolts to the torque settings specified at the beginning of this Chapter. Tighten the downpipe nuts first.

6. Run the engine and check that there are no exhaust gas leaks.

5»1

^{Chapter 5}

Ignition system

Contents

General information 1

Ignition control unit - check, removal and installation 5

Ignition (main) switch - check, removal and installation .see Chapter 9

Ignition HT coils - check, removal and installation 3

Ignition system - check 2

Ignition timing - general information and check 6

Degrees of difficulty

Neutral switch - check and replacement see Chapter 9

Pulse generator coil assembly - check, removal

and installation 4

Sidestand switch - check and replacement see Chapter 9

Spark plugs - gap check and renewal see Chapter 1

Easy, suitable for novice with little experience

Fairly easy, suitable |k for beginner with ^

some expenence

Fairty difficult, |k

suitable for competent ^ DIY mechanic !|S

£k

Difficult, suitable for experienced DIY 5J mechanic ^

₁₅

Very difficult,

suitable for expert DIY JQ or professional JN

Specifications

Note: Where applicable, models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details.

General information

Cylinder numbering (from left-hand to right-hand side of the bike) 1-2

Spark plugs see Chapter 1

Ignition timing

At idle 14° BTDC

Full advance 33° BTDC

Pulse generator coil

Resistance 450 to 550 ohms @ 20°C