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

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