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EXHAUST SYSTEM


B ENGINE

                                                                                                                                                       A




                                                                                            SECTION
                                                                                           EXHAUST SYSTEM
                                                                                                                      EX                               EX



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                                                            CONTENTS
PREPARATION .......................................................... 2
                                                                 .           Checking Exhaust System ....................................... 3
                                                                                                                                             .         F
 Commercial Service Tools ....................................... 2
                                                                 .           Removal and Installation ......................................... 3
                                                                                                                                             .
EXHAUST SYSTEM .................................................. 3
                                                                 .            REMOVAL ............................................................ 4
                                                                                                                                             .
                                                                              INSTALLATION .................................................... 4
                                                                                                                                             .         G
                                                                              INSPECTION AFTER INSTALLATION ................. 5              .

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Revision: 2005 July                                                   EX-1                                                               2005 FX
                           PREPARATION

PREPARATION                                                                 PFP:00002

Commercial Service Tools                                                       ABS005Z4



  Tool name                                      Description

  Power tool                                     Loosening nuts and bolts




                                     PBIC0190E




Revision: 2005 July           EX-2                                          2005 FX
                                         EXHAUST SYSTEM

EXHAUST SYSTEM                                                                                        PFP:20100
                                                                                                                        A
Checking Exhaust System                                                                                      ABS005Z5


Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.                                                                                 EX
q   If anything is found, repair or replace damaged parts.

                                                                                                                        C


                                                                                                                        D

                                                                                                          SMA211A

                                                                                                                        E
Removal and Installation                                                                                     ABS005Z6


CAUTION:
q  Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat                     F
   resistance, corrosion resistance, and shape.
q  Perform the operation with the exhaust system fully cooled down because the system will be hot
   just after engine stops.
                                                                                                                        G
q  Be careful not to cut your hand on the heat insulator edge.
                                                  VQ35DE
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                                                                                                     PBIC1583E

   1.   Main muffler                2.   Mounting rubber             3.   Main muffler mounting bracket
   4.   Mounting rubber             5.   Center muffler              6.   Gasket
   7.   Exhaust front tube          8.   Gasket                      9.   Collar

Revision: 2005 July                                 EX-3                                               2005 FX
                                            EXHAUST SYSTEM

     10. Grommet                       11. Exhaust mounting bracket   12. Grommet
     13. Mounting rubber               14. Bracket                    15. Ground cable
     16. Ring gasket

                                                      VK45DE




                                                                                                      PBIC1775E

     1.   Main muffler                 2.   Mounting rubber           3.   Main muffler mounting bracket
     4.   Mounting rubber              5.   Center muffler            6.   Dynamic damper
     7.   Gasket                       8.   Exhaust front tube        9.   Gasket
     10. Mounting bracket              11. Exhaust mounting bracket   12. Collar
     13. Grommet                       14. Grommet                    15. Mounting rubber
     16. Bracket                       17. Ground cable               18. Ring gasket

REMOVAL
q     Disconnect each joint and mounting using power tool.
q     When removing main muffler, remove main muffler mounting bracket bolts.
q     Remove exhaust mounting bracket as follows:
1.    Remove engine rear undercover.
2.    Remove front cross bar. FSU-6, "FRONT SUSPENSION ASSEMBLY" .
3.    Remove exhaust mounting bracket.
INSTALLATION
Note the following, and install in the reverse order of removal.




Revision: 2005 July                                    EX-4                                                2005 FX
                                       EXHAUST SYSTEM

q   Tighten main muffler mounting bracket bolts in numerical order
    as shown in the figure.                                                                                   A


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                                                                                                              C

                                                                                                  PBIC1049E

                                                                                                              D
CAUTION:
q  Always replace exhaust tube gaskets with new ones when reassembling.
q  If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat     E
   insulator, remove them.
q  When installing heat insulator avoid large gaps or interference between heat insulator and each
   exhaust pipe.                                                                                              F
q  Remove deposits from the sealing surface of each connection. Connect them securely to avoid
   gases leakage.
q  Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-             G
   cle side. Check each part for unusual interference, and then tighten them to the specified torque.
q  When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
   left directions.                                                                                           H
INSPECTION AFTER INSTALLATION
q   Make sure clearance between tail tube and bumper is even.
                                                                                                               I
q   With engine running, check exhaust tube joints for gas leakage and unusual noises.
q   Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
    stress. Improper installation could result in excessive noise and vibration.
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Revision: 2005 July                              EX-5                                            2005 FX
                      EXHAUST SYSTEM




Revision: 2005 July        EX-6        2005 FX



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