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2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
2 SCHEMATIC DRAWING
2
2-0
2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
SERVICE INFORMATION ...................... 2-1 EXHAUST MUFFLER REMOVAL .........2-5
FRAME COVERS ..................................... 2-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
· When removing frame covers, use special care not to pull them by force because the cover joint
claws may be damaged.
Items Related for Removal
· Handlebar front cover Handlebar rear cover
Headlight wire connector
· Handlebar rear cover Speedometer cable and instrument light
wire connectors, etc.
· Frame body cover Met-in box, rear grip, rear turn signal
lights, floor board
· Floor board Frame body cover
Battery and wire connectors
· Front tool box Front cover, floor board
TORQUE VALUES
Exhaust muffler joint lock nut 1.0~1.4kgf-m
Exhaust muffler lock bolt 3.0~3.6kgf-m
2-1
2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
Screw
FRAME COVERS
FRONT COVER REMOVAL
Remove the screw on the front of the front
cover.
Remove the six screws on the back of the
front cover.
Remove the front cover.
The installation sequence is the reverse of
removal.
Front Cover Screws
Handlebar Front Cover Handlebar Rear Cover
HANDLEBAR FRONT/REAR COVER
REMOVAL
HANDLEBAR FRONT COVER REMOVAL
Remove the handlebar front cover screw.
Remove the two screws attaching the
handlebar front cover.
Disconnect the headlight wire connector and
remove the handlebar front cover.
Screw Screws
HANDLEBAR REAR COVER REMOVAL
Disconnect the speedometer cable, right and Handlebar Front Cover
left handlebar switch couplers, and the stop
switch wire connectors.
Remove the bolt attaching the handlebar rear
cover.
Remove two screws inside the handlebar rear
cover and remove the handlebar rear cover.
The installation sequence is the reverse of
removal.
Bolt
2-2
2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
Bolt
MET-IN BOX REMOVAL
Open the seat and remove the two nuts and
three bolt attaching the met-in box.
Remove the met-in box .
Bolts
Center Cover
FRAME BODY COVER REMOVAL
Remove the center cover.
Rear Carrier
Remove the three bolts attaching the rear
carrier.
Remove the rear carrier.
Remove the four bolts on the rear seat.
Remove the rear seat
Bolts Bolts
Screws
Remove the six screws on the rear part of the
frame body cover.
Remove the two screws on the front of the
frame body cover.
Screws
2-3
2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
Seat Lock Wire Frame Body
Discornnect the seat lock wire. Cover
Remove the frame body cover.
The installation sequence is the reverse of
remove
Remove the three bolts attaching each of the
right and left side covers.
Remove the right and left side covers.
During removal, do not pull the joint
claws forcedly to avoid damage.
When installing, be sure to connect the
seat lock wire.
Bolts
FLOOR BOARD REMOVAL
Remove the rear carrier and rear seat. ( 2-3)
Remove the met-in box. ( 2-3)
Remove the frame body cover. ( 2-4)
Remove the eight bolts attaching the floor
board.
Remove the floor board.
Floor Board.
Bottom Protector Cover
BOTTOM PROTECTOR COVER
REMOVAL
Remove the sixbolts on the bottom protector
cover.
Remove the bottom protector cover.
Bolts
2-4
2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50
Leg shield Decorative Ring
LEG SHIELD REMOVAL
Remove the bolt leg shield.
Remove the ignition switch decorative ring
Remove the leg shield.
Bolt
Bolts
F RONT FENDER REMOVAL
Remove the two bolts attaching the front
fender bracket.
Remove the front fender.
Front Fender
EXHAUST MUFFLER REMOVAL
Remove the two exhaust muffler joint lock
nuts.
Remove the two exhaust muffler lock bolts.
Remove the exhaust muffler.
Remove the exhaust muffler joint packing
collar.
When installing, first install the exhaust
muffler packing collar and then install the
exhaust muffler. Bolts
First install and tighten the exhaust muffler
joint lock nuts. Then, install and tighten the
exhaust muffler lock bolts.
Torques:
Exhaust muffler lock bolt: 3.0~3.6kgf-m
Exhaust muffler joint lock nut: 1.0~1.4kgf-m
Be sure to install a new exhaust muffler
packing collar.
Lock Nut
2-5