Monthly Archives: Февраль 2014

COMPONENT LOCATION

COMPONENT LOCATION

SERVICE INFORMATION

GENERAL

AWARNING

• Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion result­ing in serious injury.

• 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 by pressing the valve core. Then remove the valve from the shock absorber.

• Keep grease off of the brake pads and disc.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.

• When servicing the rear wheel or suspension support the motorcycle using a workstand or equivalent under the engine.

• For optimum suspension performance and linkage component service life, the swingarm and shock linkage pivot bear­ing (along with related seals and bushings) should be disassembled, cleaned, inspected for wear and lubricated with multi-purpose grease NLGI No.2 (molybdenum disulfide additive) every 7.5 hours of operation (competition use only).

• Optional rear wheel sprockets, drive chain, shock springs and spring preload pin spanners are available. For optional parts (page 1-37).

• For brake system information (page 16-3).

• Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.

SPECIFICATIONS

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Cold tire pressure

98 kPa (1.0 kgf/cm5, 14 psi)

Axle runout

0.20 (0.008)

Wheel rim runout

Radial

2.0 (0.08)

Axial

2.0 (0.08)

Wheel hub-to-rim distance

See page 15-11

Drive chain slack

25-35 (1.0- 1.4)

60 (2.4)

Drive chain width

13.4 (0.53)

Drive chain size/link

DID

520MXV/114

Drive chain slider thickness

5.0 (0.20)

Drive chain roller O. D.

Upper

39(1.5)

Lower

35 (1.4)

Shock

Damper gas pressure

980 к Pa (10.0 kg/cm*, 142 psi)

absorber

Damper compressed gas

Nitrogen gas

Recommended shock oil

Pro Honda HP Fork Oil 5W or equivalent

Damper rod compressed force at 12 mm compressed

20.0-24.0 kgf (44.1 -52.9 Ibf)

Standard oil capacity

395 cm3 (13.4 US oz, 13.9 Imp oz)

Spring installed length

’05 — ’07

258.5 (10.18)

(standard)

After ’07

258.0 (10.16)

High speed side compression

’05 — ’07

3/4 — 1-1/4 turns out from full in

damping adjuster standard position

After ’07

7/12 — 1-1/12 turns out from full in

Low speed side compression damping adjuster standard position

10 clicks out from full in

Rebound damping adjuster standard

’05-’07

11 — 14 clicks out from full in

position

After ’07

10 — 13 clicks out from full in

TORQUE VALUES

Rear axle nut

128 N m (13.1 kgf-m, 94 Ibf ft)

U-nut

Rear spoke

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

Rear rim lock

12 N-m (1.2 kgf-m, 9 lbf-ft)

Driven sprocket nut

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

U-nut

Rear bake disc nut

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

U-nut

Rear wheel bearing retainer

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

Shock absorber upper mounting nut

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

U-nut

Shock absorber lower mounting nut

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

U-nut

Shock absorber damper rod end nut

37 N-m (3.8 kgf-m, 27 lbf-ft)

Stake

Shock absorber compression damping adjuster

29 N-m (3.0 kgf-m, 21 lbf-ft)

Stake

Shock absorber spring lock nut

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

Drive chain roller bolt

12 N-m (1.2 kgf-m, 9 lbf-ft)

Drive chain roller nut

12 N-m (1.2 kgf-m, 9 lbf-ft)

U-nut

Shock arm nut

(swingarm side)

53 N-m (5.4 kgf-m, 39 lbf-ft)

Apply oil to the threads

and flange surface, U-nut

(shock link side)

53 N-m (5.4 kgf-m, 39 lbf-ft)

Apply oil to the threads and flange surface, U-nut

Shock link nut

(frame side)

53 N-m (5.4 kgf-m, 39 lbf-ft)

Apply oil to the threads and flange surface, U-nut

Swingarm pivot nut

88 N-m (9.0 kgf-m, 65 lbf-ft)

U-nut

Drive chain guide mounting bolt/nut

12 N-m (1.2 kgf-m, 9 lbf-ft)

U-nut

Drive chain slider screw

4.2 N-m (0.4 kgf-m, 3.1 lbf-ft)

Apply locking agent to the threads

Rear brake hose guide screw

1.2 N-m (0.1 kgf-m, 0.9 lbf-ft)

Drive chain adjuster lock nut

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

Sub-frame upper mounting bolt

(’05-’07)

30 N-m (3.1 kgf-m, 22 lbf-ft)

Sub-frame lower mounting bolt

(’05 — ’07)

49 N-m (5.0 kgf-m, 36 lbf-ft)

Sub-frame upper/lower mounting

bolt

(After ’07)

49 N-m (5.0 kgf-m, 36 lbf-ft)

Left step bracket mounting bolt

(upper)

(lower)

55 N-m (5.6 kgf-m, 41 lbf-ft) 30 N-m (3.1 kgf-m, 22 lbf-ft)

TOOLS

Spoke wrench, 6.6 mm 070MA-KZ30100

Slider guide, 16 mm 07PMG-KZ40100

Driver

07949-3710001

COMPONENT LOCATION

COMPONENT LOCATION

or equivalent commercially avail­able in U. S.A.

not available in U. S.A.

Driver

07749-0010000

Attachment, 28 x 30 mm 07946-1870100

Attachment, 40 x 42 mm 07746-0010900

COMPONENT LOCATION

COMPONENT LOCATION

COMPONENT LOCATION

Attachment, 24 x 26 mm 07746-0010700

Pilot, 19 mm 07746-0041400

Pilot, 20 mm 07746-0040500

rfih

COMPONENT LOCATION

COMPONENT LOCATION

Pilot, 22 mm 07746-0041000

Pilot. 25 mm 07746-0040600

Bearing remover head, 25 mm 07746-0050800

COMPONENT LOCATION

COMPONENT LOCATION

COMPONENT LOCATION

Bearing remover shaft 07GGD-0010100

Retainer wrench, 48 mm 07YMA-KZ40100

or 07HMA-KS70100 (U. S./

>

c

о

Retainer wrench body 07710-0010401

Pin spanner (2 required) 07702-0020001

or Pin spanner A

89201-KS6-810 (2 required)

Piston ring guide 070MG-KZ30100

not available in U. S.A.

Collar, 23 x 17 mm 07GMD-KT8A110

Attachment, 30 mm I. D. 07746-0030300

TROUBLESHOOTING

Soft suspension

• Weak shock absorber spring

• Incorrect suspension adjustment

• Oil leakage from damper unit

• Tire pressure too low

• Nitrogen gas leakage from the reservoir

Stiff suspension

• Damaged shock absorber spherical bearing

• Bent damper rod

• Damaged swingarm pivot bearings

• Damaged suspension linkage bearings

• Bent swingarm pivot

• Incorrect suspension adjustment

• Tire pressure too high

Steers to one side or does not track straight

• Bent rear axle

• Axle alignment/chain adjustment not equal on both sides

Rear wheel wobbles

• Bent rim

• Worn rear wheel bearings

• Faulty tire

• Tire pressure too low

• Faulty swingarm pivot bearings

Rear wheel turns hard

• Faulty rear wheel bearings

• Bent rear axle

• Rear brake drag

• Drive chain too tight

Rear suspension noise

• Faulty rear shock absorber

• Loose rear suspension fasteners

STEERING STEM

REMOVAL

BOLTS/COLLARS

Remove the following:

— Front visor (’05 — ’07: page 3-5, After ’07: page 3­6)

— Handlebar (page 14-32)

— Front wheel (page 14-8)

After ’07: Remove the steering damper (page 14-38).

Remove the bolts, collars and front fender.

FRONT FENDER

BOLTS/BRAKE HOSE GUIDES

STEERING STEM

’05 — ’07 shown!^^^^ BOU7TRIPMETER CABLE GUIDE

Remove the bolts and brake hose guides. Remove the bolt and tripmeter cable guide.

’05-’07: TRIPMETER

trTpmeter^ Ці

GUIDE

NUTS/WASHERS

STEERING STEM

OS — ’07: Remove the nuts, washers, tripmeter and connector stay.

NUTS

BOLT

After ’07:

STEERING STEM

After ’07. Remove the nuts, cable guide and tripmeter. Remove the bolt and connector stay.

Remove the steering stem nut and washer. Remove the forks (page 14-13).

NUT/WASHER

STEERING STEM SOCKET

ADJUSTING NUT

STEERING STEM

Remove the fork top bridge.

STEERING STEM

TOP BRIDGE

Remove the steering stem adjusting nut using the special tool.

TOOL:

Steering stem socket 07916-3710101 or

07702-0020001 (U. S.A. only)

UPPER BEARING

STEERING STEM

STEERING STEM

’05-’07 shown: DUST SEAL

Remove the upper dust seal, upper tapered roller bearing and steering stem.

Check the bearings and outer races for wear or damage.

BEARING REPLACEMENT

Always replace the bearings and races as a set.

BALL RACE REMOVER

STEERING STEM

Remove the upper and lower bearing outer races from the head pipe using the special tools.

TOOL:

Ball race remover 07946-3710500

Install a new lower outer race, bearing race install­ers and installer shaft as shown.

INSTALLER SHAFT

BEARING RACE INSTALLERS

LOWER OUTER RACE

STEERING STEM

Hold the shaft with a wrench and turn the installer to install the lower outer race.

TOOLS:

07VMF-K230100

07VMF-KZ30200

Bearing race installer (2 required)

Installer shaft

INSTALLER SHAFT UPPER OUTER RACE

STEERING STEM

BEARING RACE INSTALLERS

Install a new upper outer race, bearing race install­ers and installer shaft as shown.

Hold the shaft with a wrench and turn the installer to install the upper outer race.

TOOLS:

07VMF-KZ30100

07VMF-KZ30200

Bearing race installer (2 required)

Installer shaft

Temporarily install the stem nut to avoid damaging the steering stem threads.

’05 — ’07 shown: STEERING STEM

LOWER BEARING

DUST SEAL

STEERING STEM

LOWER

STEM NUT ■ca^ DUST SEAL

STEERING STEM

Remove the lower tapered roller bearing and dust seal from the steering stem.

Apply urea based multi-purpose grease with extreme pressure to the dust seal lips.

Install a new dust seal.

Install the lower bearing using a hydraulic press and the special tool as shown.

TOOL:

Attachment, 30 mm I. D. 07746-0030300

INSTALLATION

NOTE:

’05 — ’07 shown: DUST SEAL

UPPER BEARING

• Use water resistant grease #2 (urea based multi­purpose grease) for the steering bearings and dust seals:

— Excelite EP2 (Kyodo Yushi)

— Stamina EP2 (Shell) or equivalent

Pack the upper and lower tapered roller bearings with grease.

Apply grease to all of the bearing surfaces.

Install the upper tapered roller bearing in the steer­ing head.

Slide the steering stem into the steering head from the bottom.

Install the upper dust seal.

STEERING STEM SOCKET

STEERING STEM

’05 — ’07 shown: TOP BRIDGE

NUT/WASHER

’05 — ’07:

STEERING STEM

‘05 — ‘07:

TRIPMETER

tripmetefP Ц

GUIDE

STEERING STEM

NUTS/WASHERS After ’07:

BOLT

NUTS

STEERING STEM

After ’07:

Install the steering stem adjusting nut.

Tighten the steering stem adjusting nut to the speci­fied torque using the special tool.

TORQUE: 30 N m (3.1 kgf m, 22 lbf-ft)

TOOL:

Steering stem socket 07916-3710101 or

07702-0020001 (U. S.A. only)

Move the steering stem lock-to-lock several times to seat the bearings.

Loosen the adjusting nut to torque of 0 N-m (0 kgf-m, 0 lbf-ft), and retighten to the specified torque.

TORQUE: 7.0 Nm (0.7 kgf m, 5.2 Ibf ft)

Recheck that the steering stem moves smoothly without play or binding.

Install the top bridge and washer.

Loosely install the stem nut.

Insert the forks (page 14-30).

Tighten the stem nut to the specified torque.

TORQUE: 108 N-m (11.0 kgf-m, 80 Ibf ft)

Recheck the steering stem adjustment by turning the top bridge lock-to-lock and checking for smooth­ness.

There should be no binding.

Install the tripmeter, cable guide, nuts and tighten the nuts securely.

Install the connector stay, bolt and tighten the bolt securely.

Install the connector stay, tripmeter, washers and tighten the nuts securely.

Install the tripmeter cable guide and tighten the bolt securely.

khown-ЩІ jr"",

4PMETER CABLE GUIDE

STEERING STEM

Install the front brake hose guides and tighten the bolts to the specified torque.

TORQUE: 5.2 N m (0.5 kgf m, 3.8 Ibf ft)

Install the front fender, collars and tighten the bolts securely.

After ’07: Install the steering damper (page 14-38).

Install the following:

— Front wheel (page 14-12)

— Handlebar (page 14-34)

— Front visor (’05 — ’07: page 3-5, After ’07: page 3­6)

CLUTCH LEVER

REMOVAL/INSTALLATION

CLUTCH LEVER PIVOT BOLT

CLUTCH LEVER

STEERING STEM

Remove the clutch lever pivot nut, bolt, collar, clutch lever and hot start lever.

Apply grease to the sliding surface of the clutch lever pivot bolt.

Install the clutch lever, hot start lever, collar, clutch lever pivot bolt and nut.

Tighten the pivot bolt to the specified torque. Loosen the pivot bolt to 45° — 90°, and tighten the pivot nut to the specified torque.

TORQUE:

Clutch lever pivot bolt:

2.0 N m (0.2 kgf m, 1.5 Ibf ft) — 45° to 90 Clutch lever pivot nut:

10 N m (1.0 kgf m, 7 Ibf ft)

SHOCK LINKAGE

15-30

COMPONENT LOCATION…………………… 15-2

HPSD (Honda Progressive Steering Damper): After ’07

REMOVAL/INSTALLATION

HPSD (Honda Progressive Steering Damper): After '07

HPSD (Honda Progressive Steering Damper): After '07

Clean and apply a locking agent to the steering damper mounting bolts.

Install the steering Install the steering damper, collars and bolts.

• The upper side collar is shorter than the lower side collar.

• Check that the stopper ring side of the damper rod is facing toward the front.

Tighten the steering damper bolts to the specified torque.

TORQUE: 20 N-m (2.0 kgf m, 15 Ibf-ft)

clamper onto the steering head pipe with its "UP" mark facing up and facing toward the front.

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

Check that the steering moves smoothly from side- to-side.

Install the front visor (page 3-5).

INSPECTION

Remove the steering damper (page 14-38).

Visually inspect the steering damper for wear or damage.

HPSD (Honda Progressive Steering Damper): After '07

Check the following:

— Damper case for deformation or oil leakage

— Damper rod for bending or damage

Replace the damper case or damper rod if neces­sary.

Measure the damper rod length with the ‘inside’ jaws of a vernier caliper.

SPHERICAL BEARING

DAMPER ROD

HPSD (Honda Progressive Steering Damper): After '07

Fully extend and compress the damper rod by hand. Release the damper rod then check that it extends to its maximum length.

STANDARD (maximum length):

117.55 — 118.35 mm (4.628 — 4.659 in)

Check the damper rod for smooth operation.

If the damper rod operation is not smooth, check the damper rod for bends or damage.

If the damper rod does not extend to maximum, dis­assemble the steering damper (page 14-40).

Check the spherical bearings for wear or damage. Move the spherical bearing with your finger. The spherical bearing should move smoothly and qui­etly.

Replace the spherical bearing if it does not move smoothly or quietly.

Install the steering damper (page 14-38).

SPHERICAL BEARING REPLACEMENT

SPHERICAL BEARING

HPSD (Honda Progressive Steering Damper): After '07

Remove the steering damper (page 14-38).

Remove the stopper ring.

Press the spherical bearing out of the damper mounts.

HPSD (Honda Progressive Steering Damper): After '07

Press a new spherical bearing into the damper mounts using the special tool.

HPSD (Honda Progressive Steering Damper): After '07

Drive the bearing in evenly; do not allow it to tilt.

TOOL:

Collar 07KPF-VD60100

Install a new stopper ring into the groove of the damper mounts securely.

HPSD (Honda Progressive Steering Damper): After '07

Set a 7 mm bolt and nut to the spherical bearing as shown.

Measure the stabled rotation torque of the spherical bearing inner by rotating the bolt.

STANDARD: 0.04 Nm (0.004 kgf m. 0.03 Ibf ft) max.

Install the steering damper (page 14-38).

DISASSEMBLY

END CAP/O-RING

HPSD (Honda Progressive Steering Damper): After '07

Record the damping force adjuster position.

Remove the steering damper (page 14-38).

Clean the damper assembly thoroughly.

Install a 4 mm screw to the end cap.

Remove the snap ring while pushing the end cap, and then remove the end cap and O-ring.

HPSD (Honda Progressive Steering Damper): After '07

RETURN SPRING

Remove the washers and return spring from the damper case.

Install a 8 mm screw to the free piston, then remove the free piston and O-ring.

Drain the damper oil from the damper case.

HPSD (Honda Progressive Steering Damper): After '07

Remove the plug bolt and O-ring.

O-RING

PLUG BOLT

HPSD (Honda Progressive Steering Damper): After '07

Remove the adjuster piece from the damper case.

ADJUSTER PIECE

Always replace the damper rod assembly with a new one.

Remove the dust seal.

Remove the snap ring from the damper case groove.

HPSD (Honda Progressive Steering Damper): After '07

DUST SEAL

SNAP RING

Remove the damper rod assembly out of the damper case.

DAMPER CASE

HPSD (Honda Progressive Steering Damper): After '07

Check the damper case inner surface for abnormal scratches.

Replace the damper case if necessary.

DAMPER ROD ASSEMBLY

HPSD ASSEMBLY

NOTE:

• When assembling the steering damper, follow the procedures below.

• Clean the inner surface of the damper case thor­oughly.

• Bleed the air completely in oil.

• Always replace the damper rod as an assembly with a new one.

ADJUSTER PIECE

O-RING

DAMPER CASE

& O-RING

DAMPER ROD ASSEMBLY

О o-ring end cap

SNAP RING

HPSD (Honda Progressive Steering Damper): After '07

Si!

PLUG BOLT

DAMPER PISTON

O-RING SNAP RING DUST SEAL

RETURN SPRING

Check that the Pour recommended damper oil into a suitable con — damperoil tainer until the steering damper is fully submerged. temperature is 20°С <68°F). RECOMMENDED DAMPER OIL:

HPSD (Honda Progressive Steering Damper): After &#39;07

Pro-Honda HP Fork Oil 5W or equivalent

• Check the damper oil for contamination.

• Do not allow foreign materials to enter the damper oil.

Submerge the damper case into the oil.

Submerge the damper rod into the oil.

Bleed any trapped air at the O-ring seating surface by turning the O-ring.

Shake a new damper rod assembly until there are no air bubbles.

• Be careful not to damage the damper rod and damper piston, especially around the damper rod sliding surface.

HPSD (Honda Progressive Steering Damper): After &#39;07

Bleed any air out from the damper case and damper

piston following the procedure below:

1. Install the damper piston into the damper case, pump the damper rod quickly.

NOTE.

• To open the piston valve, pump the piston rod quickly.

2. Remove the damper piston from the damper case.

3. Bring any air out from the damper case by using your finger as shown.

4. Repeat steps 1 to 3 until there are no air bubbles in the damper case and damper piston 3 times for complete air bleeding.

Install the damper rod into the damper case care­fully.

Install the snap ring to the damper case groove.

Keep the damper case submerged in

oil.

SNAP RING

In oil:

FREE PISTON

lnoil: DUST SEAL

O-RING C$5*

Fully seated:

HPSD (Honda Progressive Steering Damper): After &#39;07

• Be careful not to damage or deform the snap ring.

• Be certain the snap ring is firmly seated in the groove.

Install the dust seal to the damper case until it is flush with the damper case surface.

Fully extend the damper rod.

Bleed any trapped air at the O-ring seating surface by turning the O-ring.

Install a new O-ring to the free piston.

Install and push the free piston fully into the damper case while holding the damper rod at maximum length.

• Check that the free piston is fully seated to the damper case.

Keep the damper assembly submerged in oil.

In oil:

ADJUSTER PIECE

O-RING

-► : OIL FLOW

In oil:

PLUG BOLT

HPSD (Honda Progressive Steering Damper): After &#39;07

Bleed any trapped air at the O-ring seating surface by turning the O-ring.

Make sure the adjuster knob moves freely before tightening the plug bolt.

Install and tighten the plug bolt securely.

NOTE:

Oil is displaced as the adjuster piece and plug bolt are installed into the damper case. The displaced oil causes the free piston to move slightly as shown in the illustration.

Check that the damper rod is fully extended to its maximum length.

Install a new O-ring to the plug bolt.

Install the adjuster piece into the threads of the damper case and thread it one turn.

HPSD (Honda Progressive Steering Damper): After &#39;07

07AMJ-MENA100

Remove the steering damper from the oil.

Drain the damper oil from the sub tank.

Gauge the depth between the spring seating surface of the free piston and surface of the damper case using the special tool as shown.

COLLAR

SHOULDERED

END

PROBE

HPSD (Honda Progressive Steering Damper): After &#39;07

(In)

1.14

(mm)

Г 29

1.12

• 28.5

1.10

— 28

1.08

— 27.5

1.06

— 27

104

— 265

102

■ 26

1.00

L 25.5

Max. Standard

20

40

HPSD (Honda Progressive Steering Damper): After &#39;07

60 CC)

Before using the tool, make sure that the shoul­dered end of the probe is extending from the collar side of the depth gauge.

Insert the collar of the depth gauge into the sub tank. Loosen the thumb screw and lower the shoul­dered end of the probe until it stops.

I Tighten the thumb screw and remove the tool.

Measure the depth of the free piston with a caliper by measuring the distance between the end of the probe and the collar.

STANDARD:

27.3 — 27.9 mm (1.07 — 1.10 in) at oil temperature 20°С (68°F)

Measure the oil temperature.

If measured temperature is other than 20° С (68° F), refer to the oil chart (page 14-45).

If the measured depth is other than the standard length, disassemble the steering damper and start over.

The depth of the free piston will change according to the oil temperature as shown.

unit: mm (in)

Depth

Max.

Standard

Min.

Ll_

с

a

0

0/32

28.8(1.13)

28.5(1.12)

28.2 (1.11)

10/50

28.3(1.11)

28.0(1.10)

27.7 (1.09)

20/68

27.9 (1.10)

27.6(1.09)

27.3(1.07)

30/86

27.5 (1.08)

27.2 (1.07)

26.9 (1.06)

40/104

27.0 (1.06)

26.7(1.05)

26.4(1.04)

50/122

26.6 (1.05)

26.3(1.04)

26.0 (1.02)

TOOL:

Depth gauge

HPSD (Honda Progressive Steering Damper): After &#39;07

l_

32

140CF)

Out of oil

4 mm SCREW

END CAP

HPSD (Honda Progressive Steering Damper): After &#39;07

Be certain the snap ring is firmly seated in the groove.

Thread a 4 mm screw to the end cap and install a new snap ring to the damper case while pushing the end cap until the snap ring groove appears.

Out of oil:

HPSD (Honda Progressive Steering Damper): After &#39;07

DAMPER ROD

Check the operation of the damper rod, pump it slowly, extend or compressed by hand.

Check the following:

— Oil leakage

— Abnormal noise by trapped air

If you hear abnormal noise by trapped air, reassem­ble the steering damper.

Measure the damper rod length with the ‘inside’ jaws of a vernier caliper.

Out of oil:

HPSD (Honda Progressive Steering Damper): After &#39;07

Measure the length between the spherical bearings as shown:

STANDARD:

Fully compressed damper rod length:

93.55 — 94.35 mm (3.683 — 3.715 in)

Fully extended damper rod length:

117.55 — 118.35 mm (4.628 — 4.659 in)

If the measured lengths are outside the standard length, disassemble the steering damper and start over.

NOTE:

The normal operation of the HPSD can not be secured when the fully compressed damper rod length is more than standard.

Return the damping force adjuster to its original position.

STANDARD POSITION:

9 clicks out from full in

Install the steering damper (page 14-38).

HANDLEBAR

REMOVAL

Remove the handlebar pad from the handlebar.

HANDLEBAR PAD

HANDLEBAR

ENGINE STOP BUTTON BOLTS WIRE

HANDLEBAR

Remove the wire bands.

Remove the screw and engine stop button.

Remove the bolts and clutch lever holder.

Remove the bolts and front brake master cylinder holder.

MASTER CYLINDER

HANDLEBAR

HOLDER BOLTS

Do not disconnect the hydraulic line. Keep the brake master cylinder upright to prevent air from entering the hydraulic system.

STARTER SWITCH HOUSING

WIRE BANDS

HANDLEBAR

Remove the wire bands.

Remove the screws and engine starter switch hous­ing.

’05 — ’06 shown: THROTTLE HOUSING

HANDLEBAR

BOLTS

If you will not disassemble the throttle housing, remove the throttle housing as an assembly as fol­lows.

Loosen the throttle housing bolts, turn the handle­bar to the right fully, then remove the throttle hous­ing.

If you will disassemble the throttle housing, remove the dust cover and bolts.

’05 — ’06 shown: DUST COVER

THROTTLE HOUSING

HANDLEBAR

BOLTS

Remove the throttle housing from handlebar. Disconnect the throttle cables from the throttle pipe.

THROTTLE PIPE

, THROTTLE CABLES

HANDLEBAR

FORWARD

LOWER HOLDER

LOWER HOLDERS

HANDLEBAR

Loosen the handlebar lower holder nuts.

Remove the bolts, upper holders and handlebar. Remove the nuts, washers, bushings and lower holders.

INSTALLATION

Install the bushings, lower holders, washers and handlebar holder nuts as shown (standard position).

The lower holder standard position as shown.

• By turning the lower holder 180 degrees, you can install it 6 mm (0.24 in) rearward of the standard position. By installing the optional lower holder, you can set it 3 mm (0.12 in) rearward of the standard position.

180 DEGREES TURN

STANDARD HOLDER

OPTIONAL LOWER HOLDER POSITION

STANDARD

HOLDER

POSITION

HANDLEBAR

— Standard: 3 mm (0.12 in) offset to forward

— Standard 180 degrees turn: 3 mm (0.12 in) off­set to rearward

— Optional: No offset

Loosely install the handlebar and upper holders.

HANDLEBAR

LOWER HOLDERS|

NUTS/WASHERS/BUSHINGS

HANDLEBAR

PAINT MARK

Align the paint mark on the handlebar with the top of the lower holder.

Place the upper holder on the handlebar with the punch marks facing forward.

Install and tighten the front handlebar upper holder bolts first, then tighten the rear bolts to the specified torque.

TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)

Tighten the handlebar lower holder nuts to the specified torque.

PUNCH MARKS

HANDLEBAR

BOLTS

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

If you did not disassemble the throttle housing, apply grease to the sliding surface of the throttle pipe.

Install the throttle housing, aligning the end of the housing with the paint mark on the handlebar. Tighten the throttle housing upper bolt first, then the lower bolt.

Adjust the throttle grip freeplay (page 4-9).

If you disassemble the throttle housing, install it as follows:

THROTTLE BOLT

THROTTLE CABLES

HANDLEBAR

Apply oil to the throttle pipe sliding surface.

Apply grease to the throttle cable end and sliding area.

Connect the throttle cables to the throttle pipe. Install the throttle housing, aligning the end of the housing with the paint mark on the handlebar. Tighten the throttle housing upper bolt first, then the lower bolt.

Tighten the throttle bolt to the specified torque. TORQUE: 4 N m (0.4 kgf m, 3.0 Ibf-ft)

Install the throttle housing dust cover.

Adjust the throttle grip freeplay (page 4-9).

HANDLEBAR

If the handlebar grips are removed, apply Honda Bond A or Pro Honda Handgrip Cement (U. S.A. only) to the inside of the grip and to the clean sur­faces of the throttle pipe and the left end of the han­dlebar.

Allow the adhesive to dry for approximately 1 hour before using.

Wait 3-5 minutes and install the grip.

Rotate the grips for even application of the adhe­sive.

INDEX LINE

PAINT MARK

”Д" MARK

HANDLEBAR

Align the "Д" mark on the left grip with the paint mark on the handlebar.

Align the mark on the right grip with the edge of the throttle grip end.

WIRE BANDS

HANDLEBAR

Align the engine start switch housing as shown. Install and tighten the screws to the specified torque.

TORQUE: 1.15 N-m (0.1 kgf m, 0.8 Ibf-ft)

Install the wire bands.

Position the brake master cylinder on the handlebar.

PAINT MARK

"UP" MARK

BOLTS

HANDLEBAR

Install the master cylinder holder with its "UP" mark facing up and align the end of the holder with the paint mark on the handlebar.

Tighten the upper master cylinder holder bolt first, then tighten the lower bolt.

TORQUE: 9.9 N-m (1.0 kgf-m, 7.3 Ibf ft)

ENGINE STOP BUTTON PAINT MARK

HANDLEBAR

CLUTCH LEVER BRACKET/HOLDER PAINT MARK

Install the clutch lever bracket and holder with the punch mark on the holder facing up.

Align the end of the holder with the paint mark on the handlebar.

Tighten the upper bolt first, then the lower bolt securely.

SCREW/WASHER

HANDLEBAR

Install the engine stop button on the handlebar. Align the end of the holder with the paint mark on the handlebar.

Install the engine stop button screw with the washer and engine stop button wire terminal.

Tighten the engine stop button screw to the speci­fied torque.

TORQUE: 1.5 N m (0.2 kgf-m, 1.1 Ibf ft)

WIRE BANDS

HANDLEBAR

Route the wire Clamp the engine stop button/clutch switch wire

properly (’05 — ’07: with wire bands. page 1-25, After ’07: page 1-32).


HANDLEBAR PAD

Install the handlebar pad.

HANDLEBAR

-NT4 iv

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