3.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 4.5kg-m 3.3kg-m 2.7kg-m 6.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION SPECIFICATIONS Item Radial Axial Front shock absorber spring free length Brake disk thickness Brake disk runout Brake master cylinder I.D. Brake master cylinder piston O.D. Brake caliper piston O.D. Brake caliper piston I.D. Standard (mm) æ æ æ 200 35_ 3.8 æ 12.700_ 12.743 12.657_ 12.684 25.400_ 25.405 25.318_ 25.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK STEERING HANDLEBAR Brake Master Cylinder REMOVAL Remove the handlebar front and rear covers. (!12-3) Remove two bolts attaching the left brake lever holder. Remove two bolts attaching the brake master cylinder (disk brake) to the right brake lever. Bolts Remove the two right handlebar switch housing bolts and separate the housing. Disconnect the throttle cable and then remove the throttle pipe from the handlebar.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Install the handlebar, aligning the tabs of the handlebar with the grooves in the steering stem. Install and tighten the handlebar lock nut. Torque: 4.5_ 5.0kg-m Lubricate the throttle pipe front end with grease. Install the throttle grip and connect the throttle cable. The installation sequence is the reverse of removal. Install the rear brake lever holder. Install the front brake master cylinder (disk brake).
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL Speedometer Cable REMOVAL (DISK BRAKE) Jack the motorcycle front wheel off the ground. Remove the speedometer cable set screw and disconnect the speedometer cable. Remove the front axle nut and pull out the axle. Remove the front wheel. Remove the brake panel side collar. Axle Nut INSPECTION Set the axle in V blocks and measure the runout. The actual runout is _ of the total indicator reading. Service Limit: 0.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Turn the wheel bearings and replace them if they have excessive play or noise. Play Axial Play Radial Dust Seal DISASSEMBLY Remove the dust seal. Remove the wheel bearings and distance collar.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing . Install the distance collar. Drive in the right bearing. ＊ Drive the bearing squarely with the sealed end facing out. Pilot Apply grease to the dust seal lip and install the dust seal. Install the side collar.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL INSTALLATION (Disk Brake) Install the front wheel, aligning the speedometer gear tab with the front fork groove. Connect the speedometer cable. Torque: 5.0_ 7.0kg-m HYDRAULIC BRAKE (FRONT BRAKE) Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Pad/Disk Replacement ＊ The brake pads must be replaced as a set to ensure the balance of the brake disk. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Remove the brake pads. Front Brake Caliper Install the brake pads in the reverse order of removal. Torque: 1.5_ 2.0kg-m Front Brake Caliper ＊ Keep grease or oil off the brake pads to avoid brake failure.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system. ＊ Brake Master Cylinder Bolts • When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid. • When removing the brake fluid pipe bolt, be sure to plug the pipe to avoid brake fluid leakage.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D. Service Limit: 12.6mm Before assembly, inspect the lst and 2nd rubber cups for wear. Assembly Before assembly, apply brake fluid to all removed parts. Install the spring together with the 1st rubber cup.
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Place the brake master cylinder on the handlebar and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint. First tighten the upper bolt and then tighten the lower bolt. Torque: 1.0_ 1.4kg-m Punch Mark Bolts “Up” Mark Install the brake fluid pipe with the attaching bolt and two sealing washers. Install the handlebar covers.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Disassembly Remove the brake caliper seat from the brake caliper. Brake Caliper Seat Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston. Check the piston cylinder for scratch or wear and replace if necessary.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 25.45mm Check the caliper cylinder for scratch or wear and measure the cylinder bore. Service Limit: 25.30mm Assembly Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Installation Install the brake caliper and tighten the two bolts. Torque: 2.9_ 3.5kg-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 3.0_ 4.0kg-m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. (!13-5) Remove the front fender. (!12-6) Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers. Front Shock Absorber Mount Bolt Circlip LEFT FRONT SHOCK ABSORBER DISASSEMBLY Remove the dust boot. Remove the circlip.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Use a vise to hold the front shock absorber tube and remove the damper from the shock absorber tube. ＊ When holding the shock absorber tube, place a shop towel under it and do not apply too much force. Measure the front shock absorber spring free length.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Install the damping spring to the damper and then install them into the front shock absorber tube. Install the front shock absorber spring and tighten the damper nut. ＊ Install the front shock absorber spring with the loosely wound coils facing up. Damper Nut Front Shock Absorber Use a vise to hold the front shock absorber. Tighten the hex bolt.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Install the front shock absorbers onto the steering stem. Install and tighten the front shock absorber upper mount bolts. Tighten the lower mount bolts. Install the front fender. Install the front wheel. (!13-8) Mount Bolts Mount Bolts Front Shock Absorber FRONT FORK Lock Nut Socket Wrench REMOVAL Remove the steering handlebar.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel. Drive a new bottom cone race into place with a proper driver. ＊ Be careful not to damage the steering stem and front fork. Bottom Cone Race Ball Race Remover BALL RACE REPLACEMENT Drive out the ball races. Drive in new ball races. Driver Handle A ＊ Be sure to drive the ball races into place completely.
13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race. Apply grease to the ball races again and then install the front fork. Apply grease to the top cone race and install it. Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely.
