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4. Inspect for missing decals and/or reflectors.
INSTALLING
1. Place the rack into position on the frame and front
fender panel. Install the cap screws and lock nuts and
finger-tighten only.
2. Install the two cap screws and lock nuts securing the
rack to the fenders. Tighten all hardware securely.
Front Bumper Assembly
REMOVING
1. Remove the two front cap screws securing the front
rack to the bumper support tubes; then remove two
cap screws and nuts securing the bumper support
tubes to the frame.
2. Remove the through-bolt and lock nut securing the
bumper to the frame; then remove the bumper.
CLEANING AND INSPECTING
1. Clean all bumper components with parts-cleaning
solvent.
2. Inspect all welds for cracking or bending.
INSTALLING
1. Place the front bumper assembly into position and
install the through-bolt. Start the lock nut and fin-
ger-tighten only.
2. Install the existing fasteners in the upper support
tubes to frame and the front rack cap screws. Tighten
the lock nut (from step 1) to 20 ft-lb; then tighten the
cap screws securely.
Exhaust System
REMOVING MUFFLER
1. Remove the two exhaust springs at the muf-
fler/exhaust pipe juncture.
KC170
2. Slide the muffler rearward to clear the mounting lugs
and remove the muffler. Account for a grafoil seal.
INSPECTING MUFFLER
1. Inspect muffler externally for cracks, holes, and
dents.
2. Inspect the muffler internally by shaking the muffler
back and forth and listening for rattles or loose debris
inside the muffler.
NOTE: For additional details on cleaning the muf-
fler/spark arrester, see Periodic Maintenance - Muf-
fler/Spark Arrester.
INSTALLING MUFFLER
1. Using a new grafoil seal, place the muffler into posi-
tion engaging the mounting lugs into the grommets;
then slide the muffler forward.
2. Install the two exhaust springs.
Seat
REMOVING/INSTALLING
1. To remove the seat, lift up on the latch release
(located at the rear of the seat). Raise the rear of the
seat and slide it rearward.
2. To lock the seat into position, slide the front of the
seat into the seat retainers and push down firmly on
the rear of the seat. The seat should automatically
lock into position.
Lights
Rotate the ignition switch to the lights position; the head-
lights and taillights should illuminate. Test the brake-
lights by compressing the brake lever. The brakelights
should illuminate.
HEADLIGHTS
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure.
1. Remove the protective rubber boot from the rear of
the headlight housing; then remove the wiring har-
ness connector from the back of the headlight bulb.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.