Monthly Archives: Февраль 2014

DAMPER DISASSEMBLY

Point the valve away from you to prevent debris getting in your eyes.

Depress the valve core to release the nitrogen from the reservoir (page 15-15).

AWARNING

The chamber cap will be under significant pressure and could cause serious injury. Release all nitrogen pressure before disas­sembly.

Wear protective clothing and adequate eye protection to prevent injury and debris entering your eyes.

Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock absorber.

DAMPER DISASSEMBLY

Remove the damping adjuster.

Drain most of the shock oil from the damper and reservoir, by pumping the damper rod in and out several times.

DAMPER DISASSEMBLYDAMPER DISASSEMBLYSet the shock absorber in a vise with a piece of wood or soft jaws to avoid damage.

DAMPER DISASSEMBLY

STOPPER RING

Remove the end plate and tape or tie it to the rubber stopper so it will not get in the way.

Push in the rod guide case until you have good access to the stopper ring.

Two small screwdrivers are required to remove the stopper ring. The stopper ring groove in the damper case is ramped towards the inside to give the stop­per ring a square shoulder on which to seat securely.

ROD GUIDE CASE

SCREWDRIVER

To remove the stopper ring, first push one end of the stopper ring out of its groove, then slip the sec­ond screwdriver between the stopper ring and the damper case to act as a ramp.

Now, use the other screwdriver to pull the stopper ring completely out.

Check the stopper ring groove for burrs.

Burrs will damage the damper rod piston ring.

STOPPER RING

DAMPER ROD ASSEMBLY

DAMPER CASE

DAMPER DISASSEMBLY

Remove any burrs with fine emery cloth pulling the damper rod out of the case.

Carefully pull the damper rod assembly out of the damper case.

BLADDER REPLACEMENT

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Replace the bladder when oil leaks around the chamber cap or oil spills out when releasing the nitrogen from the reservoir.

• Perform this procedure before draining the oil from the damper.

Point the valve away from you to prevent debris getting in your eyes

Depress the valve core to release the nitrogen from

the reservoir.

AWARNING

The chamber cap will be under significant pressure and could cause serious injury. Release all nitrogen pressure before disas­sembly.

Wear protective clothing and adequate eye protection to prevent injury and debris entering your eyes.

Remove the valve core.

BLADDER REPLACEMENT

Put a suitable tool on the chamber cap and push it in by lightly tapping on the tool with a plastic ham­mer until you have good access to the stop ring.

BLADDER REPLACEMENT

Depress the chamber cap just the minimum amount for stopper ring access.

NOTICE

To avoid damaging the threads of the gas valve, install the valve cap before depressing the chamber cap.

Two small screwdrivers and a shop towel are required to remove the stopper ring.

To avoid damaging the inside surfaces of the reservoir, cover the screwdriver with a shop towel.

The stopper ring groove in the reservoir is ramped toward the inside to give the stopper ring a square shoulder on which to seat securely.

To remove the stopper ring, first push one end of the stopper ring out of its groove, then slip the sec­ond screwdriver between the stopper ring and the reservoir to act as a ramp.

Now, use the other screwdriver to pull the stopper ring completely out.

• Check the stopper ring groove for burrs. Remove any burrs with a fine emery cloth before pulling the damper rod out of the case.

BLADDER REPLACEMENT

Set the shock absorber in a vise with a piece of wood or soft jaws to avoid damage.

Using a suitable squeeze bottle, fill the reservoir with the recommended shock oil.

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent

Slowly pump the damper rod until no air bubbles appear in the valve core hole, then pull the damper rod all the way out.

VALVE CORE

CHAMBER CAP

BLADDER REPLACEMENT

Install the valve core securely.

Wear protective clothing and a face guard to protect your eyes and face in case the chamber cap pops out quickly and forcibly.

Remove the chamber cap and bladder following the procedure below:

NOTE:

• The chamber cap will be removed with hydraulic pressure so its force can be significant consider­ing the air in the bladder.

1. Wrap the shop towel around the chamber cap. Compress the damper rod slowly, to force the chamber cap out.

2. Set the damper in a vise with soft jaws with the damping adjuster facing up, being careful not to distort the damper body. Remove the damping adjuster and O-rings.

DAMPING ADJUSTER

BLADDER REPLACEMENT

NOTICE

Do not over-tighten the vise. Damage to the clamper case will result.

BLADDER REPLACEMENT

3. Fill the damper with Pro Honda HP Fork Oil 5W or equivalent through the damping adjuster hole, while slowly pulling the damper rod out.

4. Reinstall the damping adjuster after filling the damper.

• The damper must be kept upright to prevent oil from leaking out.

BLADDER REPLACEMENT

Do not use any son o1 tool to remove the bladder, because it may damage the chamber cap.

6. Repeat steps 1 to 5 until the chamber cap is removed from the reservoir.

Remove the bladder from the chamber cap.

BLADDER REPLACEMENT

Do not reuse the bladder.

Attach a new bladder to the chamber cap.

If the bladder becomes distorted during installation, depress the valve core to reform it.

5. Place the damper with the reservoir chamber cap facing up.

Clean the inside of the reservoir and fill it with rec­ommended shock oil.

BLADDER REPLACEMENT

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent

Apply light coat of shock oil to the lip of the bladder, and press the chamber cap into the reservoir to about 1.0 — 2.0 mm (0.04 — 0.08 in) below the stop­per ring groove.

Be sure the stopper ring is seated in the ring groove all the way around or the chamber cap can come apart when riding the motorcycle.

Install the stopper ring in the groove of the reservoir securely.

Temporarily fill the reservoir with air slowly until the chamber cap seats against the stop ring.

EQUAL HEIGHT CHAMBER CAP

BLADDER REPLACEMENT

Make sure the chamber cap face is level with the reservoir face.

If the chamber cap does not seat fully, the chamber cap may fly out when filling the reservoir with nitro­gen.

Release the air from the reservoir by depressing the valve core.

Bleed the air from the shock absorber bladder (page

15-26).

Fill the reservoir with nitrogen to the specified pres­sure (page 15-27).

BLADDER REPLACEMENT

RESERVOIR

BLADDER REPLACEMENT

DAMPING ADJUSTER

SHOCK ABSORBER

REMOVAL

SHOCK ABSORBER

SUB-FRAME

Remove the seat (page 3-3).

Remove the fuel tank (page 3-8).

Raise the rear wheel off the ground by placing a workstand or equivalent under the engine.

Loosen the air cleaner connecting boot band screw.

i

SHOCK ABSORBER

Remove the sub-frame lower mounting bolts and loosen the upper mounting bolt.

Do not lift past 90? Be careful not to damage the wires and cables.

Lift the sub-frame as shown.

Tighten the sub-frame upper mounting bolt to the specified torque.

TORQUE:

’05 — ’07: 30 N m (3.1 kgf m, 22 Ibf ft)

UPPER BOLT

SHOCK ABSORBER

After ’07:49 N m (5.0 kgf m, 36 Ibf ft)

If you plan to Remove the shock absorber upper mounting bolt

Remove the shock absorber lower mounting bolt, , nut and shock absorber.

disassemble the and nut. shock absorber, loosen the spring lock nut and adjusting nut.

DISASSEMBLY

Measure the spring length for reinstallation later.

SPRING SEAT

SHOCK ABSORBER

Set the shock absorber upper mount in a vise with a piece of wood or soft jaws to avoid damage.

Loosen the lock nut and adjusting nut.

TOOLS.

Pin spanner 07702-0020001 (2 required) or

LOCK NUT

SPRING

STOPPER RING

SHOCK ABSORBER

Pin spanner A 89201-KS6-810 (2 required)

Remove the stopper ring, spring seat and spring.

SHOCK ABSORBER

VALVE CORE

SHOCK ABSORBER

REAR WHEEL

REMOVAL

REAR WHEEL

Raise the rear wheel off the ground by placing a workstand or equivalent under the engine.

Loosen the axle nut.

Loosen the drive chain adjuster lock nuts and turn the adjusters clockwise fully.

Remove the axle nut and washer.

Push the rear wheel forward to derail the drive chain from the driven sprocket.

damage the brake pads with the disc.

Be careful not to Remove the axle, adjusting blocks and rear wheel.

Do not operate the brake pedal after removing the rear wheel. To do so will cause difficulty in fitting the brake disc between the brake pads.

Remove the right and left side collars.

INSPECTION

AXLE

REAR WHEEL

Set the axle on V-blocks and measure the runout. Turn the axle and measure the runout using a dial indicator.

Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in)

REAR WHEELWHEEL BEARING

REAR WHEEL

WHEEL BEARING

Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub.

Replace the wheel bearings in pairs.

Replace the bearings if the inner race does not turn smoothly, quietly, or if outer race fits loosely in the hub.

WHEEL RIM

REAR WHEEL

Check the rim runout by placing the wheel in a truing stand.

Spin the wheel by hand, and read the runout using a dial indicator.

Actual runout is 1/2 the indicator reading.

SERVICE LIMITS:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Check the spokes and tighten any that are loose.

DISASSEMBLY

05-’07 shown

BOLTS/NUTS

Remove the bolts, nuts and brake disc. Remove the right dust seal.

BRAKE DISC

DUST SEAL

BOLTS/NUTS/WASHERS

Remove the driven sprocket bolts, nuts and wash­ers.

Remove the driven sprocket.

Remove the left dust seal.

DUST SEAL

DRIVEN SPROCKET

BEARING REMOVER HEAD

*RETAINER WRENCH

Ml 1 tl

REAR WHEEL

Remove the bearing retainer using the special tools. TOOLS:

Retainer wrench, 48 mm 07YMA-KZ40100 or

07HMA-KS70100 (U. S.A. only) Retainer wrench body 07710-0010401

Install the remover head into the bearing.

From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub.

Remove the distance collar and drive out the bear­ings.

TOOLS:

Bearing remover head, 25 mm 07746-0050800 Bearing remover shaft 07GGD-0010100

Replace the wheel bearings in pairs. Do not reuse the old bearings

BEARING REMOVER SHAFT

ASSEMBLY

BRAKE DISC BOLT

DISTANCE COLLAR

BRAKE DISC

RIGHT DUST SEAL

RIGHT WHEEL

BEARING

BRAKE DISC NUT 16 N-m (1.6 kgf-m, 12 lbf-ft)

SPOKE 3.7 N-m (0.4 kgf-m, 2.7 lbf-ft)

DRIVEN SPROCKET NUT 32 N-m (3.3 kgf-m, 24 lbf-ft)

RIGHT SIDE COLLAR

RETAINER 44 N m (4.5 kgf-m, 32 lbf-ft)

After ’07:

DRIVEN SPROCKET

LEFT SIDE COLLAR

LEFT WHEEL BEARINGS

12 N-m (1.2 kgf-m, 9

lbf-ft)

LEFT DUST SEAL

REAR WHEELREAR WHEEL

REAR WHEELPlace the hub in the center of the rim, and begin lac­ing with new spokes.

45.5 ± 1.00 mm (1.79 ±0.04 in)

REAR WHEEL

Adjust the hub position so the distance from the hub left end surface to the side of the rim is 45.5 ±

1.0 mm (1.79 ±0.04 in) as shown.

Torque the rear spoke in two or three progressive steps.

TOOL:

Spoke wrench. 6.6 mm

070MA-K230100 or equivalent commer­cially available in U. S.A.

TORQUE: 3.7 N-m (0.4 kgf m, 2.7 Ibf ft)

SPOKE WRENCH

DRIVER

SETTING VALVE RUBBER

VALVE NUT

TUBE

REAR WHEEL

REAR WHEEL

REAR WHEEL

LEFT: BEARINGS

SEAL

Never install the old bearings; once the bearings have been removed, they must be replaced with new ones.

Pack all bearing cavities with grease.

Drive in a new right bearing using the special tools. TOOLS:

Driver 07749-0010000

Attachment, 40 x 42 mm 07746-0010900

Pilot, 25 mm 07746-0040600

• Drive the right bearing in the wheel hub until it is fully seated with the marking side facing up.

Install the distance collar into place, then drive the left inner and outer bearings using the same tools as shown.

• Drive the left inner bearing in the wheel hub until it is fully seated with the sealed side facing down.

• Drive the left outer bearing in the wheel hub until it is fully seated with the sealed side facing up.

Install the rear rim lock, setting rubber, tube and tire.

Tighten the rear rim lock to the specified torque. TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft)

REAR WHEELApply grease to new bearing retainer threads.

RETAINER WRENCH BODY

Install and tighten the bearing retainer to the speci­fied torque using the special tools.

TOOLS:

Retainer wrench, 48 mm 07YMA-KZ40100 or

07HMA-KS70100 (U. S.A. only) Retainer wrench body 07710-0010401

TORQUE: 44 N m (4.5 kgf m, 32 Ibf ft)

* RETAINER WRENCH

RETAINER

Peen the edge of the retainer.

BOLTS/NUTS/WASHERS

Install the driven sprocket.

Install the bolts, washers and nuts, and tighten the nuts to the specified torque.

TORQUE: 32 Nm (3.3 kgf m, 24 lbf-ft)

Apply grease to new left dust seal lips, then install the dust seal.

DUST SEAL

DRIVEN SPROCKET

05-’07 shown

BOLTS/NUTS

BRAKE DISC

Install the brake disc onto the wheel hub with the minimum thickness mark (MIN TH 3.5 mm) facing out.

Install the bolts/nuts.

Tighten the nuts to the specified torque.

TORQUE: 16 N-m (1.6 kgf m, 12 Ibf ft)

Apply grease to new right dust seal lips, then install the dust seal.

MARK b)

*3» DUST SEAL

REAR WHEELINSTALLATION

REAR WHEEL

LEFTSIDE COLLAR

RIGHT SIDE COLLAR

Install the right and left side collars.

CALIPER BRACKET

If the rear brake caliper bracket is removed, install it onto the slide rail of the swingarm.

SLIDE RAIL

Be careful not to damage the brake pads with the disc.

DRIVE CHAIN

LOCK NUT

Place the rear wheel into the swingarm.

Apply thin coat of grease to the axle.

Install the drive chain over the driven sprocket. Install the adjusting block and axle from the left side.

ADJUSTER

ADJUSTING

BLOCK

AXLE

LOCK NUT

ADJUSTER

Install the adjusting block, washer and axle nut.

Adjust the drive chain slack (page 4-24).

Tighten the axle nut to the specified torque.

TORQUE: 128 Nm (13.1 kgf m, 94 lbf-ft)

Snug the adjusters against the adjusting blocks and tighten the lock nuts to the specified torque.

TORQUE: 27 N m (2.8 kgf m, 20 lbf-ft)

ADJUSTING

BLOCK

AXLE NUT/WASHER