Service Information Troubleshooting Left Handlebar
Contents
1. Requisite Service Front brake fluid draining air bleeding u u Ls el Procedure Q ty Remarks Disassembly Order T Assembly is in the reverse order of disassembly 1 Brake oil bolt hose 1 4 NOTE Do not twist the hose At installation install the hose with the joint pipe facing toward the fork 2 Sealing washer 2 3 Pad 2 Removal installation page 14 2 4 Caliper mounting bolt 2 NOTE Loosen the torx bolts before removing the mounting bolts 5 Brake caliper assembly 1 6 Torx bolt 4 NOTE u At installation tighten after installing the caliper mounting bolts 7 Caliper piston large diameter 2 CAUTION 8 Caliper piston small diameter 2 Mark the piston to ensure that they are reinstalled in their original positions 9 Dust seal 4 CAUTION s Piston seal 4 Be careful not to damage the caliper cylinders Brake System Rear Master Cylinder Disassembly Assembly 67 5 mm 2 66 in 13 BRAKE FLUID 5 23 12 1 2 9 1 4 8 Brake System Check the brake system by applying the brake after the air bleeding CAUTION an Avoid apilling fluid on painted plastic or rubber serviced material to enter the system L T ZE C Y A parts Place a rag over these parts whenever the syst m is2. Rear Wheel Suspension Axle Needle Bearing Replacement 1 DRIVER Press the needie bearing out of the bearing holder Driver 077490010000 7 i Attachment 42 x 47 mm 07746 0010300 x i 2 ATTACHMENT Pilot 40 mm 07746 0040900 Grease the new needle bearing and press it into the bearing _ holder until it bottoms 1 DRIVER A NA Driver 07749 0010000 2 ATTACHMENT Attachment 62 x 68 mm 07746 0010500 per o y i Rear Wheel Suspension E e s Shock Absorber Linkage Removal Installation 45 4 5 33 ION DENT x DUI e 138 Rear Wheel Suspension Do not service the shock absorber and linkage while the exhaust sysstem is hot 5 3 J Requisite Service L Seat cowling removal installation page 2 2 Procedure Q ty Remarks Removal Order Installation is in ther reverse order of removal Holder band 2 Loosen the band screws Shock absorber reservoir 1 Remove from the bracket Shock absorber upper mounting bolt 1 Removal page 13 10 Schock link to frame bolt 1 Shock absorber lower mounting bolt 1 Shock arm to swingarm bolt 1 Shock linkage assembly 1 Remove through the space between the
3. _ 12 Front _Wheel Suspension Steering Service Information Troubleshooting Left Handiebar Disassembly Assembly Right Handlebar Disassembly Assembly Front Wheel Removal Instaliation Front Wheel Disassembly Assembly Service Information 12 1 12 1 12 2 12 4 12 6_ 12 8 Fork Removal Installation 12 10 Fork Disassembly 12 12 Fork Assembly 12 13 Steering Stem Removal 12 14 Steering Stem Installation 12 16 __ Riding on damaged tims impairs safe operation of the vehicle When servicing the front wheel support the motorcycle securely with a jack or other support under the engine When installing the front wheel note the normal rotating direction Tubelegs tire removal repair and remounting procedures are covered in the section 16 of the Common Service Manual When remounting the tire note the normal rotating direction Refer to the section 14 for brake system information Refer to the section 18 for light meter and switch information Troubleshooting Hard Steering Steering head bearing adjustment nut too tight Faulty steering head bearings Damaged steering stem races insufficient tire pressure Faulty tire Steers to One Side or Does Not Track Straight Bent fork Bent front axle wheel installed incorrectly Faulty steering head bearings Bent frame Worn wheel bearing Worn swingarm pivot Front Wheel Wobbling Bent rim Worn fro
4. 8 9 10 SS 18 ii o S 11 Front Wheel Suspension Steering sns i r p a ea 5 NOTE Replace the steering bearing and races as a set Do not reuse the lock washer Requisite Service Front wheel removal page 12 6 Fork removal page 12 10 Procedure Q ty Remarks Removal Order Brake hose clamp Horn Steering stem nut cap Steering stem nut Top bridge Lock nut Lock washer Steering bearing adjustment nut Upper dust seal Upper bearing inner race Upper bearing Steering stem Lower bearing Lower bearing inner race Lower dust seal Upper bearing outer race Lower bearing outer race Disconnect the horn wires Straighten the lock washer tabs Use the steering stem socket O7HMA MR70100 Remove from the steering stem Use the driver attachment B 07946 KM90200 driver assembly shaft 07946 KM90300 bearing remover B 07946 KM90500 and base 07946 KM90600 Been nan nnn nnn nana 12 15 Front Wheel Suspension Steering sv E s 3 Steering Stem Installation Bend down the two tabs into the adjustment nut grooves and bend up two tabs into the lock nut grooves 15 18 140 14 0 101 2 SESH 5 13 12 11 Ss o 50 5 0 3
5. Do not twist the hoses 3 Sealing washer 3 i 4 Master cylinder assembly 1 Disconnect the brake switch wires and remove the holder I 5 Reservoir hose 1 H 6 Reservoir assembly 1 i 7 Brake switch 1 I 8 Brake lever pivot bolt 1 9 Brake lever assembly 1 10 Rubber cap 1 11 Snap ring 1 12 Reservoir hose joint 1 i 13 O ring 1 I 14 Piston boot i 15 Snap ring 1 Use the snap ring pliers 079143230001 CAUTION t At installation be certain the snap ring is firmly seated in the groove in the master cylinder body 16 Master piston assembly 1 NOTE T r Do not remove the piston cups from the piston 17 Spring 1 NOTE T Atinstallation install with the small coil end facing toward the primary cup gt Ta gt ed Brake System e Caliper Disassembly As sembly Front Brak ae oe O ring seal and sealing washer a 1 35 3 5 25 Brake System Dsicard contaminated pads and clean a contamicated disc with a high quality brake degreasing agent CAUTION N Check the brake system by applying the brake after the air bleeding Spilled brake fluid will damage painted plastic or rubber part S NOTE E Do not remove the bleed valve unless it is replaced
6. 15 Lower fork pinch bolt 1 14 Upper fork pinch bolt 1 3 Handlebar holder pinch bolt 2 16 Wire band 2 Front fender 1 Front fender mounting bolt 4 Support the fork and install into the groove securely Install onto the fork and raise the fork through the top bridge aligning the locating pin of the handlebar 12 11 Front Wheel Suspension Steering Fork Disassembly 14 O 145 S 17 ua S E Ni 3 5 e a S Sa 4 e E ee 8 ADJUSTER NOTE Set the pre load adjuster to the softest position before loosening the fork bolt _ Requisite Service Fork removal Installation page 12 10 Procedure Disassembly Order 1 Stopper ring 1 2 Fender bracket E 1 3 Fork bolt 1 4 Stopper seat 1 5 Fork bolt 1 6 O ring 1 7 Spring seat 1 8 Spacer 1 9 Spring seat 1 10 Fork spring 1 11 Socket bolt washer 1 1 12 Fork piston assembly 1 13 Oil lock piece 1 14 Dust seal 1 15 Stopper ring 1 16 Fork tube 1 17 Oil seal 1 18 Back up ring 1 19 Slider bushing 1 20 Fork tube bushing 1 __Remarks Remove from the fork tube NOTE Drain the fork oil from the fork tube and piston rod af ter removing Hold the pre load adjuster an
7. 5 Master cylinder mounting bolt 2 Loosely install 7 Joint pin 1 6 Cotter pin 1 Tighten the master cylinder mounting bolts after installing 4 O ring 1 3 Reservoir hose joint screw 1 1 2 Sealing washer 2 1 Brake oil bolt hose A 1 1 Rest the joint against the master cylinder boss Rear Brake Caliper Disassembly Assembly gt O ring seal and sealing washer _ 2 1 dy 35 3 5 25 Brake System Dsicard contaminated pads and clean a contamicated disc with a high quality brake degreasing agent Check the brake system by applying the brake after the air bleeding CAUTION _ he tes 2 E ons Spilled brake fluid will damage painted plastic or rubber parts E i NOTE _ SAA A _ B Do not remove the bleed valve unless it is replaced Gg i Requisite Service Rear brake fluid draining air bleeding Wa Procedure y Remarks gt gt fp Disassembly Order Assembly is in the reverse order of disassembly 1 Brake oil bolt hose w 111 CAUTION Do not twist the hose NOTE Remove the hose by loosening the joint nut while holding the hose nut 2 Sealitg washer 1 3 Caliper mounting bolt 2 NOTE Loosen the pad pin before removing 4 Pad 2 Removal installation page 14
8. When remoing the oil bolt cover the end of the brake hose to prevent contamination Do not allow the foreign Do not allow the lips of the cups to turn insie and be certain the snap ring is firmiy seated in the groove TA s mt 77 ENS io Mi ES NOTE oe i s Use only DOT 4 brake fluid from a sealed container eee SE ss Requisite Service Front brake fluid draining air bleeding Procedure Remarks o ZN Disassembly Order e s 1 y 1 Brake oil bolt hose 1 2 Sealing washer gt 3 Reservoir hose joint screw 111 14 O ring 1 5 Master sylincer mounting bolt 2 Loosen the bolts 6 Cotter pin 1 7 Joint pin 1 8 Master cylinder assembly 1 Remove from the right step braket 9 Pedal joint 1 Remove by loosening the lock nut 10 Rubber boot 4 11 Snap ring 1 Use the snap ring pliers 07914 3230001 12 Push rod 1 13 Master piston assembly 1 NOTE Do not remove the piston cups from the piston Spring 1 Assembly Order 14 Spring 1 NOTE Install with the small coil end facing toward the piston 13 Master piston assembly 1 12 Push rod 1 11 Snap ring 1 CAUTION Be certain the snap ring is firmly seated in the groove in the master cylinder body 10 Rubber boot 1 9 Pedal joint 1 NOTE Adjust joint installed length as shown 8 Master cylinder assembly 1
9. Information 13 1 Shock Absorber Linkage Removal Troubleshooting 43 4 Installation 1338 Rear Wheel Driven Sprocket Removal posk Absorber Disassembly 13 12 installation 13 2 Y r Shock Linkage Disassembly Bearing Holder Removal Installation 13 4 _ Assembly 13 14 Bearing Holder Axle Disassembly 7 Assembly 13 6 Swingarm Removal Installation 13 16 Swingarm Disassembly Assembly 13 18 ES oF 13 Rear Wheel Suspension Service Information The shock absorber contains nitrogen under high pressure Do not allow fire or heat near the shock absorber Before disposal of the shock absorber release the nitrogen Step section 19 of the Common Service Manual Drilting point spe 1 11 Riding n damaged rims impairs safe operation of the vehicle Tubeless tire removal repair and remounting procedures are covered in the section 16 of the Common Service Manual When remounting the tire note the normal rotating direction Refer to the section 14 for brake system information Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points Troubleshooting Rear Wheel Wobbling Hard Suspension Loose wheel nut _ Bent damper rod Bent rim Damaged swingarm pivot bearings Loose bearing holder Damaged shock absorber bushing Damaged axle bearing s Incorrect suspension adjustment Faulty swingarm
10. stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to cllean brake assembiles NOTE Install the front wheel with the arrow mark stamped on_the right side facing to the normal rotating direction Do not depress the brake lever when the caliper is removed or it will be difficult to refit the disc between the brake pads Requisite Service Raise the wheel off the ground by placing a jack or other support under the engine Procedure ES Q ty Remarks Removal Order NN o Y Caliper mounting bolt 4 Front caliper assembly 2 CAUTION Do not hang the caliper by the brake hose Right axle pinch bolt 2 Loosen the bolts Axle bolt 1 Left axle pinch bolt 2 Loosen the bolts Axle shaft 1 Front wheel assembly 1 Disassembly assembly page 12 8 Side collar 2 Installation Order gt es e Side collar 2 NOTE A Right side collar is longer than the left side collar Apply grease to the dust seal lips before installing Front wheel assembly 1 Axle shaft la 1 NOTE Apply thin coat of grease Axle bolt 1 Left axle pinch bolt 2 Right axle pinch bolt 2 NOTE Tighten after tightening the axle bolt Front caliper assembly 2 CAUTION Be careful not to damage the pads Caliper
11. 3 5 Caliper assembly 1 Separate the bracket from the caliper 6 Pad retainer 1 NOTE At installation note the installation direction 7 Pad retainer 1 8 Pivot boot 1 9 Pivot pin bolt 1 NOTE 10 Pivot pin bolt 1 Do not remove the pivot pin bolt unless it is replaced 11 Caliper piston 2 CAUTION Mark the piston to ensure that they are reinstalled in their original positions 12 Dust seal 2 CAUTION 13 Piston seal 2 Be careful not to damage the caliper cylinders 14 11 Brake System Rear Brake Pedal Removal Installation E 3 a _ lt NOTES i Ss Tum rr E A Z massa a _ The pedal height can be adjusted by turning the pedal joint on the master cylin AS A eae ee ee i Procedure de _ Qty _ Remarks Removal Order Installation is in the reverse order of removal 1 Spring hook plate bolt 1 2 Spring hook plate 1 3 Step bolt 1 NOTE At installation align the flats of the step and step holder 5 Brake pedal thrust washer 1 1 6 Cotter pin 1 7 Joint pin ie if It
12. 6 E 17 f E Pl a 16 Front Wheel Suspension Steering NOTE Requisite Service Fork installation page 12 10 Front wheel installation page 12 6 Check the steering bearing preload after installing Procedure Q ty Remarks Installation Order 1 Upper bearing outer race 1 Use the driver attachment B 07946 KM90200 driver 2 Lower bearing outer race 1 assembly shaft 07946 KM90300 bearing remover B 07946 KM90500 and base 07946 KM90600 3 Lower dust seal 1 4 Lower bearing inner race 1 Use the stem driver attachment O07HMD MR70100 and inner driver C 07746 0030100 5 Lower bearing 1 6 Steering stem 1 7 Upper bearing 1 8 Upper bearing inner race 1 9 Upper dust seal 1 10 Steering bearing adjustment nut 1 Use the steering stem socket O7HMD MR70100 11 Lock washer 1 Bend down the two tabs into the adjustment nut grooves 12 Lock nut 1 Hand tighten align the grooves with the lock washer tabs and bend up the tabs into the grooves 13 Top bridge 1 14 Steering stem nut 1 NOTE Temporarily install the fron forks and tighten the nut 15 Steering stem nut cap 1 16 Horn 1 Connect the horn wires 17 Brake hose clamp 1 12 17 Service
13. EDLE BEARING towing tools a 07936 3710300 07936 3710100 07741 0010201 Bearing remove Remover handie Shding weight installation Apply molybdenum disulfide grease to a new needle bearing _ end press the bearing into the shock link until it bottoms DD Driver 077490010000 Attachment 24 x 26 mm 077460010700 Pilot 17 min 07746 0040400 Shock link pivot Apply molybdenum disulfide grease to a new needle bearing and press the bearing into the shock arm until the attachment_ bottoms s od u a Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 17 mm 07746 0040400 Swingarnr pivot Apply molybdenum disulfide grease to a new needle bearing and press the bearing into the shock arm until the attachment_ bottoms _ 7 S 00L Driver Attachment 24 x 26 mm Pilot 17 mm 07749 0010000 07746 0010700 07746 0040400 biel 1 2 SLIDING WEIGHT 4 BEARING REMOVER 3 REMOVER HANDLE 1 DRIVER 3 ATTACHMENT 2 PILOT 1 DRIVER 4 NEEDLE BEARING 2 ATTACHMENT gt a B hae te 3 PILOT 1 DRIVER 3 NEEDLE BEARINGS A 13 15 Rear Wheel Suspension Swingarm Removal Installation Rear Wheel Suspension CAUTION 5 E Support the removed calip
14. N N 2 SLIDER 2 SCREW While holding the shock absorber remove the upper mounting bolt Raise the rear wheel and install the shock absorber lower mounting bolt Torque 45 N m 4 5 kg m 33 ft lb EN Pa 2 LOWER MOUNTING BOLT Install the shock link to fram bolt SHOCK LINK TO FRAME 2 UPPER MOUNTING BOLT N Torque 45 N m 4 5 kg m 33 ft Ib While supporting the rear wheel install the shock absorber upper mounting bolt and tighten it Torque 45 Nm 4 5 kg m 33 ft lb I Ga Rear Wheel Suspension Shock Absorber Disassembly Assembly 4 B 2 E a usss _ eee o PEN The shock absorber contains nitrogen under high pressure Do not allow fire or heat near the shock absorber Before disposal of the shock absorber release the nitrogen Step section 19 of the Common Service Manual Drilling point page 1 11 SoS E A a OR NOTE ns za lt A ee nose x a BALE 288 Loosen the spring pre load adjuster lock nut and adjuster nut fully for easy disassembly When the adjuster nut is loo sened adjust the spring installed length and tighten the lock nut atts se gas SEN Et ae Dt ye eae Ie Requisite Service Shock absorber linkage removal installation 13 8 m xm Q ty _ Remarks Procedure on S i Disassembl
15. Remove the wire bands Left handlebar holder 1 NOTE Remove the front wheel page 12 6 and lower the fork Assembly Order 10 Left handlebar 1 9 Left handlebar pinch bolt 1 8 Handlebar holder pinch bolt 2 NOTE Align the locating pin on the holder with the groove in the fork top bridge and tighten the upper bolt first 7 Left handlebar grip 1 6 Left hadiebar weight attaching screw 1 1 NOTE Apply locking agent to the screw thread 5 Left handlebar switch 1 NOTE Align the locating pin with the hole in the handlebar 4 Attaching screw 2 NOTE Tighten the front screw first 3 Clutch lever holder bracket 1 1 NOTE Install the holder with the UP mark facing up Clutch lever holder bolt e 2 NOTE Tighten the upper bolt first Clutch switch wire Connect to the switch terminals 12 3 3 7 Front Wheel Suspension Steering Right Handlebar Disassembly Assembly a Sy 40 4 0 29 9 e 12 1 2 9 12 4 Procedure Front Wheel Suspension Steering Remarks Disassembly Order Front brake switch wire is Front brake switch wire 2 Disconnect from the switch terminals Master cylinder holder bolt 2 Master cylinder holder 1 Brake master cylinder assembly 1 CAUTION Keep the master cylinder upright Throttle hous
16. d remove the fork bolt as shown CAUTION Do not remove the adjuster from the fork piston CAUTION Do not remove the bushing unless it is replaced A a 12 12 Front Wheel Suspension Steering Fork Assembly 20 2 0 14 16 18 Swng 15 GP De 17 Procedure I Remarks Assembly Order 1 Fork tube bushing 1 2 Slider bushing 1 Install onto the fork tube 3 Fork tube 1 4 Oil lock piece 1 install onto the end of the fork piston 5 Fork piston 1 6 Sealing washer socket bolt 1 1 NOTE Apply locking agent to the bolt threads 7 Back up ring 1 8 Oil seal 1 Use the fork seal driver 07947 KA50100 and attach ment 0797 KFOOT0OO0 9 Stopper ring 1 10 Dust seal 1 NOTE Pour fork oil to the specified level before installing the spring page 1 11 11 Fork spring 1 NOTE Install with the tapered end facing down 12 Spring seat 1 13 Spacer 1 14 Spring seat 1 15 O ring 1 16 Fork bolt 1 17 Stopper seat 1 18 Fork bolt 1 install onto the adjuster Screw into the fork tube but do not tighten yet CAUTION Be careful not to cross thread 19 Fender bracket 1 i _ 20 Stopper ring 1 E E Front Wheel Suspension Steering Steering Stem Removal 17 _ 13 14 Of 15
17. er with a piece of wire so that it does not hang from the brake hose Do not twist the brake hose NOTE T T Do not depress the pedal when the caliper is removed orit will be difficult to refit the disc between the brake pads Requisite Service Rear whee driven sprocket removal installation page 13 2 Shock absorber linkage removal installation page 13 8 Procedure Q ty Remarks Removal Order 1 Bearing holder pinch bolt hose clamp 1 1 12 Drive chain cover bolt nut de 1 1 3 Drive chain cover 1 Remove the brake hose from the clamps 4 Rear brake caliper 1 5 Pivot nut 1 Adjust bolt lock nut 1 Adjust bolt 1 Loosen by turning the pivot bolt counterclockwise with the hex wrench Pivot bolt E 1 Swingarm drive chain 1 1 Disassembly assembly page 13 19 Left pivot collar ba Installation Order Left pivot collar 1 Install into the swingarm Swingarm drive chain 1 1 Adjust bolt 1 Pivot bolt 1 Installation page 13 18 Pivot nut 1 Adjust bolt lock nut 1 Rear brake caliper 1 Drive chain cover 1 Clamp the brake hose Drive chain cover bolt nut 111 Bearing holder pinch bolt hose clamp 1 1 NOTE After installing adjust the drive chain stack page 3 11 13 17 Rear Wheel Suspension Pivot Bolt Installation Screw the adjust bolt in the left pivot by hand Appl
18. exhaust pipes Disassembly page 13 14 Shock absorber assembly 1 Disassembly page 13 12 Upper mounting collar 1 PP Rear Wheel Suspension Rear Suspension Bolt Removal Raise the rear wheel off the ground and support the motorcycle securely 1 SHOCK LINK TO FRAME BOLT Remove the seat cowling Remove the shock link to frame bolt NOTE E Loosen the nut first then remove the bolt for easy removal Remove the shock absorber upper mounting bolt while supporting the rear wheel by hand Looser the shock absorber lower mounting nut Raise the wheel further by hand and remove the shock absorber lower mounting bolt NOTE Be careful not to damage the exhaust pipe while servicing _ Remove the screw and the lower portion of the drive chain slider from the swingarm Remove the shock arm to swingarm bolt 13 10 A 3 DRIVE CHAIN SLIDER 2 SCREW Rear Wheel Suspension Rear Suspension Bolt Installation Install the shock absorber with the drain tube forward and temporarily install the upper mounting bolt Install the shock finkage assembly and install and tighten the chock arm to swingarm bolt Torque 45 Nm 4 5 kg m 33 ft lb Install the drive chain slider and screw Torque 4 N m 0 4 kg m 2 9 ft lb 3 DRIVE CHAI
19. ile holding the driven flange Driven flange 1 Install the drive chain then install aligning the splines Brake caliper 1 CAUTION Be careful not to damage the brake pads Brake caliper mounting bolt 2 Thrust washer 1 Spring washer 1 NOTE Install with the dished side facing in Lock nut 1 Use a new nut and stake it after tightening Axle bolt 1 Install a new bolt from the left side while aligning the splines when it is replaced NOTE Adjust the drive chain slack after installing the rear wheel page 3 11 13 5 Rear Wheel Suspension Bearing Holder Axle Disassembly Assembly Wheel side SIT PAR o NOTE Requisite Service Bearing holder removal installation page 13 4 Procedure 15 1 5 11 a c Replace the axle bearings as a set Remarks Bearing Holder Disassembly Order 1 Collar 2 Outer dust seal 3 Bearing set ring 4 Left bearing 6908LU 5 Right needle bearing 6 Inner dust seal Axle Disassembly Order la Brake disc bolt nut b Brake disc tc Drive pin pin bolt 2a gt unN Assembly is in the reverse order of disassembly Replacement page 13 7 Assembly is in the reverse order of disassembly 4 4 1 NOTE At assembly install with the MIN TH 5 mm mark facing toward the wheel 4 4 NOTE Carefully remove as the thread locking agent is used
20. ing screw 2 Throttle grip 1 Disconnect the throttle cable Engine stop switch 1 Remove the screws Right handlebar weight attaching screw 1 1 Handlebar holder pinch bolt 2 Loosen the bolts Right handlebar pinch bolt 1 Right handlebar 1 NOTE po Spread the slit slightly and puch the handlebar out Handlebar holder removal order Installation is in the reverse order of removal Lower fork pinch bolt 1 Loosen the bolt Upper fork pinch bolt 1 Loosen the bolt Remove the brake hose band Left handlebar holder 1 NOTE Remove the front wheel page 12 6 and lower the fork Assembly Order ar Right handlebar 1 Right handlebar pinch bolt 1 Handlebar holder pinch bolt 2 NOTE Alighn the locating pin on the holder with the groove in the fork top bridge and tighten the upper bolt first Throttle grip 1 Connect the throttle cables Throttle housing screw 2 NOTE Align the mating surface with the punch mark on the handlebar and tighten the front screw first Engine stop switch 1 NOTE Tighten the front attaching screw first Brake master cylinder assembly 1 Master cylinder holder 1 NOTE install with the UP mark facing up Master cylinder bolt 2 NOTE Align the end of the holder with the punch mark on the handlebar and tighten the upper bolt first 2 Connect to the switch terminals _ i 12 5 Front Wheel Suspension Steering A contaminated brake disc or pad reduces
21. ke pads Rear Wheel Suspension A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies di 1 NOTE Support the removed caliper with a piece of wire so that it does not hang by the brake hose Do not twist the brake hose Requisite Service Rear wheel removal installation page 13 2 Loosen the drive chain page 3 11 Procedure _ Q ty Remarks Removal Order Axle bolt 1 NOTE Tap out the bolt to the left side with a plastic hammer when it is to be replaced Lock nut 1 Loosen after unstaked Spring washer 1 Thrust washer 1 Brake caliper mounting bolt 2 Brake caliper 1 CAUTION Do not hang by the brake hose Axle brake disc assembly 1 Pull out to the right side while holding the driven flange Disassembly page 13 6 Driven flange 1 Remove from the drive chain Snap ring 1 Caliper bracket 1 Bearing holder pinch bolt 1 Fully loosen Bearing holder 1 Pull out of the swingarm Disassembly page 13 6 Installation Order Bearing holder 1 Bearing holder pinch bolt 1 Loosely install Caliper bracket 1 Snap ring 1 Axle brake disc assembly 1 Install from the right side wh
22. mounting bolt 4 12 7 Front Wheel Suspension Steering Front Wheel Disassembly Assembly Arrow marks on the wheel are stamped on the right side only 3 S 20 2 0 14 2 12 8 Front Wheel Suspension Steering A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contminated disc with a high quality brake degreasing agent NOTE gt a i 7 The left and right brake discs should be installed on the original side unless they are replaced When remounting the tire onto the wheel face the arrow marks on the wheel and tire to the same direction Do not add more than 60 g 2 1 oz of the wheel balance weight gt Always replace wheel bearings as a set Requisite Service Front wheel removal installation Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly Dust seal 2 Brake disc bolt 12 Brake disc 2 Right wheel bearing 6004UU 1 Distance collar 1 Left wheel bearing 6004UU 1 At installation drive a new left bearing into the hub first 4 then drive a new right bearing Front tire 1 NOTE At installation face the arrow mark to the same direc Saz tion as the arrow mark on the wheel 12 9 1 E Front Wheel Suspensio
23. n align the tabs with the caliper grooves as 1 shown 5 Pad 2 NOTE Push the piston all the way into provide clearance for new en ae pads sz al Bs asas Brake System 1 4 amas de Sy 17 1 7 12 2 5 0 25 1 8 ATA Ps ee A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contamicated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies After replacement operate the brake lever to seat the caliper pistons against the pads NOTE a 2 E de RE disconnecting the hydraulic system The brake pads can be replaced witho Replace the brake peds as a set u il Wah ting Apply a thin coat of grease onto the pad pin and pad plug threads so as not to rust it tas me e NA E r Me E a a i Procedure 3 Q ty Remarks _ to Removal Order E 1 Pad pin plug 1 Loosen the pad pin after removing the plug 2 Caiper mounting bolt 1 Remove the tront bolt 3 Caliper assembly 1 Pivot downward out of the disc 4 Pad pin 1 Pull out while pushing the pads in slightly 5 Pad shim 2 NOTE Push the pistons all the way in to p
24. n Steering Fork Removal Installation Loosen when the fork is TOP BRIDGE to be disassembled E 8 AS 1 w 6 R a lt 7 9 A n xX A va El mm u Om 2 e it amm m E RS NOTE Front Wheel Suspension Steering LL L LLUUUIILIIIUl a luu I iii is n When the fork is to be disassembled set the pre load adjuster to the softest position loosen the upper fork pinch bolt and loosen the fork bolt but do not remove it yet After assembling the fork tighten the fork bolt which is temporarily tightened before tightening the upper fork pinch bolt Requisite Service Front wheel removal installation page 12 6 On the right fork remove the brake hose band Lower the fork part way and remove from the fork On the right side keep the master cylinder upright holder with the top bridge groove Procedure Q ty Removal Order T 1 Front fender mounting bolt 4 2 Front fender 1 3 Handlebar holder pinch bolt 2 Loosen the bolts 4 Upper fork pinch bolt 1 Loosen the bolt 5 Lower fork pinch bolt 1 Loosen the bolt 6 Wire band 2 NOTE 7 Handlebar assembly 1 CAUTION 8 Stopper ring 1 9 Fork assembly 1 Disassembly page 12 12 Installation Order 9 Fork assembly 1 8 Stopper ring 7 Handlebar assembly 1 NOTE
25. nt wheel bearings A Faulty tire Unbalanced tire and wheel Wheel Turns Hard Faulty wheel bearing Brake drag page 14 1 Bent fron axle Soft Suspension Weak fork spring Insufficient fluid in fork Low fluid level in fork Low tire pressure Hard Suspension Incorrect fluid weight Bent fork tubes Clogged fork fluid passage High tire pressure Front Suspension Noisy Insufficient fluid in fork Loose fork fasteners 1 2 1 Front Wheel Suspension Steering Left Handlebar Disassembly Assembly b 11 1 1 8 a e 40 4 0 29 8 S 12 1 2 9 Front Wheel Suspension Steering Procedure T Q ty Remarks Disassembly Order A 1 Clutch switch wire 2 Disconnect from the switch terminals 2 Clutch lever holder bolt 2 3 Clutch lever holder bracket 1 1 4 Attaching screw 2 5 Left handlebar switch 1 6 Left handlebar weight attaching screw 1 1 17 Left hadiebar grip 1 8 Handlebar holder pinch bolt 2 Loosen the bolts 9 Left handlebar pinch bolt 1 10 Left handlebar 1 NOTE Spread the slit slightly and push the handlebar out Handlebar holder remova order Installation is in the reverse order of removal a Lower fork pinch bolt 1 Loosen the bolt Upper fork pinch bolt 1 Loosen the bolt
26. otection to avoid getting metal shav ings in your eyes when the gas pressure is released The plastic bag is only intended to shield you from the es caping gas Hold the bag around the drill motor and briefly run the drill mo tor inside the bag this will inflate the bag with air from the_ motor and help keep the bag from getting caught in the bit when you start Remove the joint hose from the damper D gt l a N a O E 13 13 ing to explosion and severe personal injury A Rear Wheel Suspension Shock Linkage Disassembly Assembly 1 3 5 N 4 45 4 5 33 Requisite Service Shock absorber linkage removal installation 13 8 Remarks Procedure Disassembly Order Assembly is in the reverse order of disassembly Shock link collar 1 Shock arm collar 1 Shock arm to shock link bolt 1 NOTE At assembly note the installation direction of the shock arm shock link and bolt Dust seal 6 Shock link needle bearing 2 Shock arm needle bearing 3 7 Shock Linkage Bearing Replacement j PIN DRIVER ASSEMBLY Removal Press the needle bearings out of the shock arm Pin driver assembly 07GMD KT80100 NOTE B Do not remove the shock absorber lower mount bushing o E 13 14 Rear Wheel Suspension Remove the needle bearings from the shock link with the fol j 1 NE
27. pivot bearing s Faulty shock linkage bearings Loose shock linkage swingarm fastener s Insufficient tubrication of suspension pivots Faulty tire Damaged mount bushing Unbalanced tire and wheel Rear Suspension Noise Soft Suspension Loose fasteners Weak spring Incorrect suspension adjustment Faulty damper unit Oil leakage from damper unit Rear Wheel Suspension Rear Wheel Driven Sprocket Removal Installation Y a SSS A gt ae EN N i Align the pins with the holes 13 2 Rear Wheel Suspension Requisite Service Raise the rear wheel off the ground and support the motorcycle N h Procedure Remarks Removal Order i 1 Center cap cotter pin 111 2 Wheel nut 1 3 Shim 1 4 Center lock spacer 1 5 Rear wheel 1 Driven Sprocket Removal Order Installation is in the reverse order of removal a Driven sprocket nut 6 b Driven sprocket 1 NOTE i Loosen the drive chain before removing page 3 11 Installation Order 5 Rear wheel 1 NOTE Align the holes with the drive pins of the axle L 4 Center lock spacer 3 Shim Wheel nut Cotter pin center cap 13 3 E Do not depress the brake pedal when the caliper is removed or it will be difficult to refit the disc between the bra
28. ring remover set 07936 3710001 Drive the needie_bearing out of the left swingarm pivot E T Needie bearing remover O7HMC MR70100 Driver shaft 07946 MJ00100 v Installation Apply molybdenum disulfide grease to a new needle bearing Carefully press the needle bearing into the left swingarm pivot 4 mm 0 16 in from the edge of the swingarm measuring with the vernier caliper Driver 07749 0010000 _ Attachment 37 x 40 mm 07746 0010200 Pilot 28 mm 07746 0041100 _ Drive ball bearings into the right swingarm pivot one by one with the marked side facing out until they bottom Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 20 mm 07746 0040500 gt install the snap ring 1 BEARING REMOVER SET REMOVER 1 DRIVER SHAFT _ 2 NEEDLE BEARING _ 1 ATTACHMENT 2 DRIVER 3 PILOT ve 14 Brake System Service Information 14 1 Front Brake Caliper Disassenbly Troubleshooting 14 1 _ Assembly 14 6 Front Brake Pad Replacement 142 pea ay Cylinder Disassembly 14 8 Rear Brake Pad Replacement 14 3 _ Rear Brake Caliper Disassembly Front Master Cylinder Disassembly Assembly 14 10 Assembly 14 4 Rear Brake Pedal_Removal Installation 14 12 Service Information A contaminated brake disc or pad reduces stopping power Discard con
29. rovide clearance for new pads Removal Order 5 Pad shim 2 Do not forget to install the shim 4 Pad pin 1 Loosely install while pushing the pads in slightly 3 Caliper accembly 1 CAUTION Be careful not to damage the pads 2 Cariper mounting bolt 1 1 Pad pin plug Tighten the pad pin before installing the plug o eS c 14 3 ed Brake System Front Master Cylinder Disassembly Assembly E 18 CAUTION _ _ A _ ___ 4F ted plastic or rubber parts Place a rag over these parts whenever the system is Brake System Check the brake system by applying the brake after the air bleeding Avoid apilling fluid on pain serviced material to enter the system When remoing the oil bolt cover the end of the brake hose to prevent contamination Do not allow the foreign certain the snap ring is firmly seated in the groove Do not allow the lips of the cups to turn insie and be NOTE _ Use only DOT 4 brake fluid from a sealed contain _ Requisite Service Front brake fluid draining air bleeding _ po Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly i 1 Brake oil bolt 1 i 2 Brake hose 2 NOTE i
30. taminated pads and clean a contaminated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies Spilled brake fluid will severely damage instrument lenses and painted surfaces It is also harmful to some rubber parts Be very careful whenever you remove the reservoir cap make sure the front reservoir is horizontal first Never allow contaminants dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brakes feel spongy the system must be bled Always use fresh DOT 4 brake fluid from a seal d container when servicing the system Do not mix different types of fluid as they may not be compatible Always check brake operation before riding the motorcycle Troubleshooting Brake Lever Pedal Soft or Spongy Air bubbles in the hydraulic system Leaking hydraulic system Contaminated brake pad disc Worn caliper piston seal Worn master sylinder piston cups Worn brake pad disc Contaminated caliper Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Contaminated master cylinder Bent brake lever pedal Brake Lever Pedal Hard Clogged restricted brake system S
31. ticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal _Brake Drag Contaminated brake pad dics Misaligned wheel Badly worn brake pad disc Warped deformed brake disc Caliper not sliding properly Clogged restricted fluid passage Sticking worn caliper piston 14 1 Brake System Front Brake Pad Replacement EZ ASE V Swa cA amam a N A A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contamicated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies After replacement operate the brake tever to seat the caliper pistons against the ads gt cl ii NOTE AA cee The brake pads can be replaced without disconnecting the hydraulic system Replace the brake peds as a set Apply a thin coat of grease onto the pad pin and pad plug threads so as not to rust it ee eck tal PPA on Procedure ee OY Remarks Removal Order Installation is in the reverse order of removal 1 Dust cover 1 2 Pad pin plug 1 3 Pad pin 1 4 Pad spring 1 NOTE Atinstallatio
32. y Order Assembly is in the reverse order of disassembly Drain tube 1 Stopper ring 1 Removal installation page 13 13 Lower spring seat 1 Spring 1 Damper unit A er _ io i 13 12 Rear Wheel Suspension 1 SHOCK ABSORBER COMPRESSOR Stopper Ring Removal Installation Install the shock absorber compressor and attachment on the shock absorber as shown Shock absorber compressor O7GME 0010000 Attachment 07959 MB10000 ry Turn the compressor handle and slowly compress the spring until the stopper ring can be removed Remove the stopper ring Install the stopper ring in the reverse order of removal Y Shock Absorber Disposal Procedure Es 1 PLASTIC BAG Center punch the center of the pressure tank cap to mark the lt lt 2 PRESSURE TANK CAP drilling point AY Wrap the pressure tank inside a plastic bag A Support the pressure tank in a vise as shown Through the open end of the bag insert a drill motor with a sharp 2 3 mm 5 64 1 8 in drill bit Do not use a dull drill bit which could cause a build up of excessive heat and pressure inside the damper lead The shock absorber contains nitrogen gas and oil under high pressure Do not drill the damper case pressure tank body or you may drill into the oil chamber oil escaping under high pressure may cause serious personal injury Always wear eye pr
33. y thin coat of grease to the pivot bolt and insert the bolt in the pivot 5 Align the hex head of the pivot bolt with the hex hole in the adjust bolt and push the pivot bolt in fully Tighten the adjust bolt by turning the pivot bolt with the hex wrench Torque 15 N m 1 5 kg m 11 ft lb Loosely install the pivot nut install the adjust bolt lock nut and tighten it while holding the pivot bolt to prevent the adjust bolt from turning Torqu 80 N m 8 0 kg m 58 ft lb e te Pivot adjust wrench 079084690001 Tighten the pivot nut Torque 95 N m 9 5 kg m 69 ft lb N w 1 ADJUST BOLT 2 PIVOT BOLT JA 2 PIVOT BOLT ADJUST BOLT 1 PIVOT ADJUST WRENCH 13 18 Rear Wheel Suspension Swingarm Disassembly Assembly 3 Le Requisite Service Swingarm Removal Installation page 13 16 Procedure Disassembly Order Drive chain slider Caliper bracket bolt Torque link bolt Right dust seal Snap ring Right pivot ball bearing Left dust seal Left pivot needle bearing Replacement page 13 20 Replacement page 13 20 Remarks Assembly is in the reverse order of disassembly 13 19 Rear Wheel Suspension Pivot Bearing Replacement Removal Remove the snap ring Remove the ball bearing trom the right swingarm pivot EN voa 7 I Z Bea
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