Reassembly (Exhaust Components)

REASSEMBLY

CAUTION:

The exhaust system operates under very high pressure from the turbocharger. Every connection and joint in the system must be tight, and new gaskets must be used. There must be no exhaust leaks or a drop in performance will result.

EXHAUST SYSTEM REASSEMBLY

CAUTION: Observe the following assembly instructions carefully. The exhaust system must be assembled in the order listed below.

1. Mount the sub-muffler and the protector to the turbocharger.

1. Protector 2. Sub-muffler

Tightening torque: 12 Nm (1.2m-kg, 8.7 ft-lb)

2. Mount the turbocharger to the frame, and finger-tighten the mounting nut.

3. Connect the ducts 1 and 2 to the turbocharger, and tighten the clamp screws.

1. Duct from air cleaner

1. Duct to surge tank

Tightening torque: 2Nm (0.2 m-kg, 1.4 ft-lb)

4. Connect the oil lines, and tighten the banjo fitting bolt.

Tightening torque. 21 Nm{2.1 m-kg, 15 ft-lb)

5.    Install the exhaust chamber to the turbocharger, and finger-tighten the mounting bolt to the frame.

6.    Tighten the flange nuts (2).

Tightening torque: 20 Nm (2.0 m-kg, 14 ft-lb)

7.    Install the exhaust pipes to the exhaust chamber, and install the ringnuts to the cylinder head.

8.    Tighten the ringnut securing nuts (8).

Tightening torque: 10 Nm (1.0 mkg, 7.2 ft-lb)

9. Tighten the clamp bolts (4)

Tightening torque. 20 Nm (2.0 m-kg, 14 ft-lb)

10. Tighten the exhaust chamber mounting bolt.

Tightening torque: 25 Nm (2.5 m-kg, 18 ft-lb)

11. Tighten the turbocharger mounting nuts (2).

Tightening torque: 20 Nm (2.0m.kg, 14 ft-lb)

12. Install the left muffler to the turbo-charger, and finger-tighten the bolt and nuts (2).

13.    Install the left footrest bracket.

14.    Tighten the coupling bolt and nuts (2).

Tightening torque: 20 Nm (2.0 mkg, 14 ft-lb)

15. Tighten the footrest bracket securing bolts (3).

Tightening torque: 25 Nm (2.5 m-kg, 18 ft-lb)

16.    Install the right muffler to the sub-muffler.

17.    Install the right footrest bracket.

18.    Tighten the clamp bolt.

Tightening torque: 20 Nm (2.0 mkg, 14ftlb)

19. Tighten the footrest bracket securing bolts.

 

Tightening torque:
	Nm	m-kg	1Mb
M8	20	2.0	14
M10	25	2.5	18