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12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the machine frame covers before removing the front wheel. Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake drum and brake linings. • Inspect the brake system before riding. SPECIFICATIONS Item Radial Axial Front wheel rim run out Front brake drum I.
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12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM FRONT WHEEL MX’er SYSTEM Nut Pin REMOVAL Place the machine on a level place. Remove four nuts attaching the wheel panel and front wheel. Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over. Nuts Remove the cotter pin. Remove nut attaching the wheel hub and washer. Remove the collar and wheel hub.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Measure the wheel run out. Replace wheel or check bearing play if out of specification Rim run out limits: Vertical: 2.0mm Lateral: 2.0mm Inspect the front wheel hub. Replace if cracks or damage. Inspect the front brake drum. Measure the front brake drum I.D. Service limits: 111mm ＊ Keep oil or grease off the brake drum. Side Collar FRONT WHEEL BEARING Remove the side collar.
12. FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Remove the dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub. Dust Seal BEARING REPLACEMENT Remove the front wheel bearings and distance collar. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. Apply grease to a new dust seal lip and install the dust seal.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM FRONT BRAKE MX’er SYSTEM Brake Lining FRONT BRAKE LINING INSPECTION Measure the front brake lining thickness. Service limit: 2.0mm replace if below ＊ Keep oil or grease off the brake linings. REMOVAL Inspect the shoe springs, O-rings, camshaft lever and wear indicator. Replace if damage. Inspect the brake shoe plate. Replace if cracks or damage. Inspect the brake shoe pivot pin. Replace if wear or damage.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Install the brake shoe plate. ＊ Make sure that the boss on the knuckle Boss correctly engages with the locating slot on the brake shoe plate. Apply the grease onto the bearings and oil seal lips of the wheel hub. Install wheel hub, plate washer and tight the nut (wheel hub). Torque: 6.0_ 8.0kgf-m Install cotter pins. ＊ ＊ Locating Slot Always use a new cotter pin. Do not loosen the axle nut after torque tightening.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM FRONT SUSPENSION MX’er SYSTEM Upper Bolt REMOVAL Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over. Remove the front wheel, wheel hub, brake shoe plate. Remove the upper and lower bolt, then remove the shock absorber. Lower Bolt Tie-rod Nut Remove the cotter pin and nut, then remove tie-rod from steering knuckle.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM INSPECTION Check the front arm brackets of the frame. If bent, cracked or damaged, repair or replace the frame. Check the tightening torque of the front arms securing nuts. Torque: 4.0_ 5.0kgf-m Check the front arm side play by moving it from side to side. If side play noticeable, replace the inner collar, bushings and thrust covers as a set. Check the front arm vertical movement by moving it up and down.
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Inspect the steering knuckle. Replace if cracks, pitting or damage. . Inspect the front arm. Replace if cracks, bends or damage. ＊ Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Bushes Inspect bushes. Replace if wear or damage. INSTALLATION Reverse the “REMOVAL” procedures. ＊ Apply the grease onto the bushes, collars and covers. Install the front arm nut onto the frame and tighten the nuts.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Apply the grease onto the bush, collars and covers, then install the steering knuckle onto the front arm and tighten the nut. Torque: 4.0_ 5.0kgf-m Install the cotter pin and band ends of cotter pin. ＊ Always use a new cotter pin. Install the tie-rod onto the steering knuckle and tighten the nut. Torque: 4.0_ 5.0kgf-m Install the cotter pin and band ends of cotter pin. ＊ Always use a new cotter pin.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Handlebar Cover STEERING SYSTEM REMOVAL Remove the following parts: Seat, Front cover, Center cover and Front fender Refer to the “FENDERS” section in the CHAPTER 2 Disconnect the main switch lead. Remove the handlebar cover with main switch. Main Switch Lead Brake Switch Disconnect the front brake cables from the brake lever, rear brake cable from the brake lever and brake switch from the bracket of the brake lever.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Remove the two screws and remove the handlebar switch. Remove the two bolts and remove headlight unit. Remove the four handlebar holder bolts and remove the handlebar. MX’er SYSTEM Screws Handlebar Switch Bolts Headlight Unit Bolts Remove the cotter pins and nuts attaching the tie-rods, then remove tie-rods.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Remove the two bolts to remove the cable holder, steering bracket, collars and steering column. Cable Holder Bolts MX’er SYSTEM Collar Steering Column Steering Bracket INSPECTION Inspect the handlebar. Replace if cracks, bends or damage. Inspect the steering column. Replace if bends or damage. ＊ Do not attempt to straighten a bent shaft, this may dangerously weaken the shaft. Oil Seal Inspect the steering brackets and oil seal.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Inspect the tie-rod. Replace if bend or damage. Check the tie-rod end movement. Replace if the tie-rod end exists free play or turns roughly. Check the tapered surface of the tie-rod end. Replace if pitting, wear or damage. Adjust the tie-rod length. Adjustment steps: (The following procedures are done on both tie-rods, right and left.) Loosen the lock nuts. Adjust the tie-rod length by tuning both tierod ends.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM ＊ MX’er SYSTEM The threads on both rod-end must be of the same length. Dust Seal Inspect the collar, duty seal, snap ring and bearing. Replace if wear or damage. Collar INSTALLATION Reverse the “REMOVAL” procedures. ＊ Apply the grease onto the collar, duty seal, and bearing. Assembly the steering column and tighten the two bolts. Torque: 3.0_ 4.0kgf-m Band the lock washer tabs.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Install the steering column and collar, then tighten the nut. Torque: 6.0_ 8.0kgf-m Install the cotter pin and band ends of cotter pin. ＊ MX’er SYSTEM Cotter Pin Nut Always use a new cotter pin. Cotter Pin Install the tie rods and tighten the nut. Torque: 4.0_ 5.0kgf-m Install the cotter pin and band ends of cotter pin. ＊ Always use a new cotter pin.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM ＊• Be sure the upper handlebar holder mark face to front. • Fist tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. Apply the grease onto the end of the throttle cable and end of the brake cable. Refer to the “TOE-IN ADJUSTMENT” section in the CHAPTER 3 to adjust toe-in. Refer to the “FRONT BRAKE ADJUSTMENT” section in the CHAPTER 3 to adjust front brake.
