Category Archives: ANUAL SERVICE M

SHOCK LINKAGE

SHOCK LINKAGE

REMOVAL

Remove the cotter pin, washer, joint pin, spring and left step.

LEFT STEP

SHOCK LINKAGE

WASHER

Remove the step bracket mounting bolts and step bracket assembly.

SHOCK LINKAGE

Remove the nut and drive chain roller.

Remove the following:

BOLT/NUT/WASHER (SWINGARM SIDE)

LOWER

BOLT/NUT

SHOCK ARM

BOLT/NUT/WASHER

BOLT/NUT/WASHER (FRAME SIDE)

BOLT/NUT/WASHER (SWINGARM SIDE)

LOWER

BOLT/NUT

SHOCK ARM

BOLT/NUT/WASHER

SIDE)

SHOCK LINKAGE

— Shock absorber lower mounting bolt/nut

— Shock arm bolt/nut/washer (shock link side)

— Shock arm bolt/nut/washer (swingarm side)

— Shock arm

— Shock link bolt/nut/washer (frame side)

— Shock link

Remove the side collars, pivot collar and dust seals from the shock link. SIDE COLLAR

SHOCK LINK

SHOCK LINKAGE

PIVOT COLLAR DUST SEAL

PIVOT COLLARS

SIDE COLLARS

SHOCK ARM

SHOCK LINKAGE

Remove the side collars and pivot collars from the shock arm (swingarm side, shock link side).

Remove the dust seals and washers (swingarm side, shock link side).

DUST SEALS SIDE COLLARS

SHOCK LINKAGE

WASHERS PIVOT COLLAR

Remove the dust seals, side collars and pivot collar (shock absorber side).

INSPECTION

SHOCK ARM: PIVOT COLLARS

SHOCK LINKAGE

Check the dust seals and collars for wear, damage or fatigue.

Check the needle bearings for damage or loose fit. Check the shock arm and shock link for cracks or damage.

If the needle bearings are damaged, replace them.

SHOCK LINK: SIDE COLLARS

SHOCK LINKAGE

PIVOT COLLAR DUST SEALS

SPHERICAL BEARING REPLACEMENT

DUST SEALS

SPHERICAL BEARING REPLACEMENT

Remove the dust seals.

Check the spherical bearing for wear or damage.

If it is worn or damaged, it must be replaced.

STOPPER RING

COLLAR

SPHERICAL BEARING REPLACEMENT

Press the spherical bearing to get the clearance nec­essary to remove the stopper ring using the special tool.

TOOL:

Collar, 23 x 17 mm 07GMD-KT8A110

Remove the stop ring.

COLLAR

SPHERICAL BEARING REPLACEMENT

ATTACHMENT

Press the spherical bearing out of the upper mount using the special tools.

TOOLS:

Collar, 23 x 17 mm 07GMD-KT8A110

Attachment, 30 mm I. D. 07746-0030300

COLLAR

SPHERICAL BEARING REPLACEMENT

Apply multi-purpose grease NLGI No.2 (molybde­num disulfide MoS2 additive) to the new spherical bearing.

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

Press a new spherical bearing into the upper mount. TOOL.

Collar, 23 x 17 mm 07GMD-KT8A110

Install a new stopper ring into the groove of the upper mount securely.

COLLAR

SPHERICAL BEARING REPLACEMENT

Press the spherical bearing into the upper mount using the special tool, until it seats against the stop­per ring.

TOOL:

Collar, 23 x 17 mm 07GMD-KT8A110

DUST SEALS

SPHERICAL BEARING REPLACEMENT

Be sure to install Apply grease to new dust seal lips and install them.

the correct dust seal in each side.

’05 — ’07 shown:

LOWER BOLT/NUT

STOPPER

UPPER BOLT

SPHERICAL BEARING REPLACEMENT

INSTALLATION

Set the shock absorber onto the shock arm with the rebound adjuster facing right side.

Install the lower mounting bolt by aligning the fiat side of the bolt with the stopper on the shock absorber.

Install and tighten the lower mounting nut to the specified torque.

SPHERICAL BEARING REPLACEMENT

UPPER NUT

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

Install the upper mounting bolt by aligning the flat side of the bolt with the groove of the frame, install and tighten the shock absorber upper mount­ing nut to the specified torque.

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

Loosen the sub-frame upper mounting bolt and connect the air cleaner connecting boot securely.

SPHERICAL BEARING REPLACEMENT

Tighten the sub-frame mounting bolts to the speci­fied torque.

TORQUE (’05 — ’07):

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

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

TORQUE (After ’07):

Upper/lower: 49 N-m (5.0 kgf-m, 36 lbf-ft)

Tighten the air cleaner connecting boot band screw securely.

Install the fuel tank (page 3-8).

Install the seat (page 3-3).

ROD GUIDE CASE INSPECTION

REBOUND RUBBER

ROD GUIDE CASE INSPECTION

METAL

ROD GUIDE CASE INSPECTION

DUST SEAL

Inspect the rebound rubber and dust seal lips for wear or damage and replace the rod guide case with a new one if necessary.

Visually inspect the rod guide case metal.

If the metal is worn so that the copper surface appears, replace the rod guide case with a new one.

Remove the O-ring from the rod guide case and replace it with a new one.

ROD GUIDE CASE

ROD GUIDE CASE INSPECTION

O-RING

DAMPER ROD INSPECTION

Inspect the damper rod sliding surface for damage or distortion.

8 mm (0.3 in) 8 mm (0.3 in)

ROD GUIDE CASE INSPECTION

DAMPER ASSEMBLY

COMPRESSION VALVES

PISTON

REBOUND VALVES

ROD GUIDE CASE INSPECTION

Before assembly, wash all parts with solvent and blow them dry with compressed air.

Make sure there is no dust or lint on any of the parts.

NOTICE

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

• Never assemble valves which might have gotten dusty or otherwise contaminated during the dis­assembly process. Disassemble them, thor­oughly clean them with solvent and blow them dry with compressed air before assembly.

VALVE STOPPER

• Use care to avoid getting solvent on the piston ring and O-ring.

ROD GUIDE CASE INSPECTION

ROD GUIDE CASE INSPECTION

Install the rubber seat, rubber stoDDer and end

n ata № RUBBER SEAT RUBBER STOPPER

• The valve arrangement and number of valves may differ from those shown.

Apply shock oil to a new O-ring, and install it to the rod guide case.

SLIDER GUIDE

O-RING

ROD GUIDE

ROD GUIDE CASE INSPECTION

Install the special tool onto the damper rod.

TOOL:

Slider guide, 16 mm 07PMG-KZ40100

not available in U. S.A.

Carefully install the rod guide case with the rebound rubber facing up, over the damper rod.

Remove the special tool.

The valve arrangement and number of valves may vary from those shown.

Install the valve stopper and compression valves onto the damper rod.

ROD GUIDE CASE INSPECTION

ROD GUIDE CASE INSPECTION

COMPRESSION VALVES

REBOUND VALVES

PISTON VALVE STOPPER

ROD GUIDE CASE INSPECTION

Install the piston onto the damper rod.

Note the installation direction of the piston valves.

Install the rebound valves with their polished sur­faces facing down.

NOTICE

Be careful not to bind the valves when installing the piston onto the damper rod. Also, check that they are concentric with the damper rod.

Install the valve stopper.

END NUT

END NUT

ROD GUIDE CASE INSPECTION

J

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

Install and tighten a new damper rod end nut to the specified torque.

TORQUE: 37 Nm (3.8 kgf m, 27 Ibf ft)

Stake the end of the damper rod in three places as shown, to the end nut.

ROD GUIDE CASE INSPECTION

DAMPER CASE

DAMPER ROD ASSEMBLY

STOPPER RING

ROD GUIDE CASE INSPECTION

Coat the damper rod with Pro Honda HP Fork Oil 5W or equivalent. Check the rod guide case by sliding it up and down fully to be sure there is no restriction.

ROD GUIDE CASE INSPECTION

Coat the damper case inner surface, piston ring and O-ring with Pro Honda HP Fork Oil 5W or equivalent, and insert the damper rod assembly carefully.

Install the stopper ring into the groove in the damper case.

After assembling, check that the stopper ring is seated in the groove of the damper case completely. You should not be able to pull the damper rod out of the damper case.

END PLATE

ROD GUIDE CASE INSPECTION

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

NOTICE

Do not over-tighten the vise and distort the damper case.

Drive the end plate squarely and evenly into the damper case with a plastic hammer.

Fill the damper case and reservoir with recom­mended shock oil through the damping adjuster hole.

SHOCK OIL

ROD GUIDE CASE INSPECTION

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent STANDARD OIL CAPACITY:

395 cm3 (13.4 US oz, 13.9 Imp oz)

Make sure the rod guide case is seated against the stopper ring by pulling the damper rod all the way out.

Do not let oil flow out of the reservoir

Slowly pump the damper rod until there are no bub­bles in the oil that overflows from the damper case.

Remove the damper unit from the vise.

SHOCK OIL

ROD GUIDE CASE INSPECTION

Position the damper unit so the damping adjuster hole faces up. Turn the damper unit as shown to bleed any air from the reservoir completely.

• When bleeding air from the reservoir, be careful to hold the damper at the angles shown so the filler hole points up.

Be sure the reservoir pressure is correct using an accurate pressure gauge

Temporarily charge the reservoir with 49 kPa (0.5 kgf/cmJ, 7.1 psi) of air slowly to inflate the bladder.

Check for any oil that may leak out of the valve while pressurizing. Replenish oil as necessary.

DAMPING

ROD GUIDE CASE INSPECTION

^ -7| O-RINGS

Fill the damper with recommended shock oil to the damping adjuster hole neck.

Apply oil to new O-rings and install them to the damping adjuster.

Dip the damping adjuster in clean shock oil.

Slowly install the damping adjuster.

Tighten the damping adjuster to the specified torque.

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

Wipe off all oil from the damper rod; oil left on the damper rod can lead to premature failure of the oil seal.

Check the oil leaks.

DAMPING ADJUSTER

Stake

ROD GUIDE CASE INSPECTION

Stake the damping adjuster as shown.

Release the air that was in the reservoir at precom­pression. Fill the reservoir with 980 kpa (10.0 kgf/ cm2,142 psi) of nitrogen gas.

VALVE CAP

ROD GUIDE CASE INSPECTION

ACAUTION

The shock absorber is fitted with a gas-filled reservoir. Use only nitrogen gas to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion resulting in seri­ous injury.

SPRING TAPERD END

SPRING SEAT

STOPPER RING

ROD GUIDE CASE INSPECTION

Install the valve cap.

Install the spring with its tapered end facing down. Install the spring seat and stopper ring.

Loosely tighten the adjusting nut and lock nut.

Turn the shock absorber lower mount so the rebound adjuster screw is on the same side of the shock reservoir.

ROD GUIDE CASE INSPECTION

SAME SIDE

ROD GUIDE CASE INSPECTION

One turn of the adjusting nut changes the spring length by 1.5 mm (0.06 in).

Turn the spring adjusting nut until the spring length measurement recorded at disassembly is reached or until the spring length is as specified below.

STANDARD SPRING LENGTH:

’05-’07: 258.5 mm (10.18 in)

After ’07: 258.0 mm (10.16 in)

Hold the adjusting nut and tighten the lock nut.

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

Use this standard spring length as the baseline.

See the Owner’s Manual for detailed instructions on adjusting preload and damping for riding conditions and rider skill.

PISTON RING REPLACEMENT

PISTON RING REPLACEMENT

PISTON RING GUIDE

PISTON RING REPLACEMENT

Apply fork oil to new O-rings and piston ring.

Place the piston ring guide attachment over the pis­ton and install new O-rings and piston ring into place by hand.

TOOL:

Piston ring guide

070MG-KZ30100 not available in U. S.A.

Compress the piston ring against the ring groove and seat the piston ring into the ring groove.

DAMPER ROD DISASSEMBLY

30° at first then gradually angle to 45°

10 mm (0.4 in)

PISTON RING REPLACEMENT

To keep lint or dirt from getting onto the damper rod parts, do not wear gloves while working on the damper rod.

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

PISTON RING REPLACEMENT

Unstake the damper rod end nut with a file as shown.

Be careful to file the end nut by hand so that the O. D. of the rod end is about 10 mm (0.4 in). Be care­ful not to over-file.

PISTON RING REPLACEMENT

Turn the end nut back-and-forth in 1/4 turn incre­ments until it loosens, then rotate another 1/4 turn and repeat turning back-and-forth until the nut loos­ens completely.

If the damper rod is cracked or damaged when removing the end nut, replace the damper rod assembly with a new one.

Remove the burrs from the damper rod end with a

PISTON RING REPLACEMENT

Make sure That filings are not stuck in the damper rod.

file and chase the threads with a die.

DIE: 12 x 1.25 mm

Clean the damper rod with solvent after chasing the

threads.

• Use a piece of mechanics wire to keep the removed valves in the correct order.

• Keep dust and abrasive away from all damper rod parts.

• Thoroughly clean the valves in solvent and blow them dry with compressed air if they have been disassembled and separated.

• Be careful not to get solvent on the O-ring and piston ring.

• The valve arrangement and number of valves shown is typical and may not represent this model exactly.

PISTON

REBOUND VALVES

VALVE STOPPER

PISTON RING REPLACEMENT

Remove the valve stopper, rebound valves and pis­ton from the damper rod.

Remove the compression valves and valve stopper.

VALVE STOPPER

PISTON RING REPLACEMENT

COMPRESSION VALVES

ROD

TAPE

GUIDE CASE

DAMPER ROD

PISTON RING REPLACEMENT

Chase the threads with a die and clean with oil. Back out the damping adjuster.

Wrap the threads of the damper rod with tape.

Remove the rod guide case from the damper rod.

Remove the end plate, rubber stopper and rubber seat from the damper rod.

RUBBER SEAT RUBBER STOPPER

PISTON RING REPLACEMENT

END PLATE