Sees. [12 | FRONT WHEEL/SUSPENSION/ STEERING ROUE AVANT/SUSPENSION/ DIRECTION VORDERRAD/AUFHANGUNG/ LENKUNG 12-0FRONT WHEEL/SUSPENSION/STEERING 85 Nem 16. 47 Ie) 12 Nam (1.2 kon Selb)FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 12-1 FRONT WHEEL 12-6 TROUBLESHOOTING 12-2 FORK 12-40 HANDLEBAR 12-3 STEERING STEM 12-18 SERVICE INFORMATION GENERAL + A conaminated brake dive or pad reduces Wapping power, Discard contaminated pads nd clean a contaminared dite with «high ‘quality Brake depressing agent. + Inhaled axbestos fibers heve been found to cause respirators disease and cancer. Never use an air Kaxe arity brush to clean brake carsemtblies, © This section covers maintenance af the frant wheel, fork and steeting stem. Refer to section 14 for front (hydraulic! Brake © Support the molnrcyele using & hoist or a jack under the engine. SPECIFICATIONS ire STANDARD SEAVIGE LIMIT Ae ano - 0-2 10.008 i ot ad Fine | Rael = 20mm (0.08in | Axia = moon | Fatal evel oT mm a2 wl | rock mute nau = 2 10.0081 Fork fll poet US on 145 Ino oo) orvepeng tee igi [A 3 mm 12,96 in Faz mm 282 cs 464.1 mn 118. 06 inl 773.3 ro (18.87 i) TORQUE VALUES Herdlebar holder tot 24 wen (24 kgm 17 He Byate dc bot isn (1s eg. 11 feb) From axe eB Nem (68 kgm, 47 tb) Front ons halder nut 12 Nom (1-2 kgm 8 fel Fark top pinch bat 33Nen (33 kgm 24 fb) Fark born pinch bat ZaNen (2.3 kam, 24 eb) Hist 23 New (2.3 kgm, 17 te) Fark coe batt 2ONm (204g 14 tb) take zatpgs mousing 28Nem (2.8 kgm 18 fob) Beeriguont a 118 Wem (11.8 cg, 6 fb Screg beaing-ediwomenenot BhemiO2 gms 4 el 12-1FRONT WHEEL/SUSPENSION/STEERING | TOOLS Special Steering stem driver Steering stern socket Ball race remover — driver attachment — driver hancie 979484300101 07918-KAE0100 97983—MJ10000 07953—ms10100 97983—MJ10200 common Driver Bearing remover head, 15 em Bearing ramaver shaft 42 35 mm 077430010000 97748 0050400 077480050100 07748 0010100 077480040300 077480010300 (077470010100 9747—0010800 Attachmone Pilot, 15 mm Attachment, 4247 mm Fork seal ceiver body Fork seal driver attachment TROUBLESHOOTING Hard Steering + Steering bearing adjustment nut too tight + Faulty steering stem bearings + Insufficient ai in front sire ‘Stosre ta One Side of Does Not Track Straight + Bont fark lage + Bent front axle, wh + Unequal oll quantity in installed incerrectty ich fork tube Front Wheel Wobbiing * Distorted rim + Woin trent whee! bearings + Loose or broken spokes + Faulty tire * Axle or axle holder not tightened praperly Soft Suspension Weak fork springs + Insufficient fluid in fork leas Hard Suapansion Fork oil level too high Fork tube(s} bent ar fork alderla} damaged Front Suspension Noise + Sider binding Insuttioient fluid in fork legs + Loose fork leg fasteners 12-2FRONT WHEEL/SUSPENSION/STEERING —_—__—eeeeeeeeeeee HENDLEBAR a ng ees AE REMOVAL ff \ Remove tha Wire bande Disconnect the front brake switch wires Remove the master eyiinder halear Remove the right handlebar éwitoh heading and disconnect the throttle cables. then remove the throttle grip end and grip CAUTION + Suspand the master cylinder, with a suitable wire, of least as high as originally installed! so a8 10 prevent air from getting fnio the brake fad. jn) switcH Remove the left hanclobar gtip and ane grip from the handlebar ae 7 HousiNG HW naeaseary. wove tha elutah lever holder. famavo tha left handleher switch and disconnect the choke cable from the choke lever Remave the bolt caps and bolts, then cemove che handlebar Upper tioldars and the handlebar, ¥ «& ee 12-3FRONT WHEEL/SUSPENSION/STEERING INSTALLATION {stall the harvlehar arf align ifs punch mark with the top of the lowar holders Place the upjinr holders omthe handiebar with the punch marke forward Flahren the forwatd bolts frst, then tighten the rear bolts TORQUE: 24 Neen (2.4 kam, 17 feb) Inst the-balt cape, It the handlebar crins were removed. apply Honda Bond A to (1) CEMENT the inside of the grip and to tha clean surfaces af the right and Jett handlebar, Wait 3-5 minutes and inatall the aria, Rotate the grip fer evan application of the adhesive. NoTE Allow the auhesive to dry lor an hur batforo usiba, Apgly a graase to tho throttle cable end. Codneet the throttle Gables to the thvottle pps Align tho i hea #9 tho Inara and tight ation pin on the'tight handlebar switsh with the anlebar the switch serews, frant screw frat, then (2) SCREWS 12-4FRONT WHEEL/SUSPENSION/STEERING (1) PUNCH MARK Placa the Irant brake master cylinder on the handlebar andl in stall tha master eylinder holelar with the "UP" mark facing up is holder with the punch mark on the handle pper halder bolt first, then tightan the lowar Align the ond of bar, Tighton the bolt Connect the front brake switch wires: (2) “UP MARK Connect the choke cable to the ehake lever 1) CHOKE CABLE Install the left handlebae switch by aligning the locating. pin Leva with tha ole in the handleber. Tighcen the front screw first, then tighten the rear sere (3) SCREWS, Install the clutch lever holder whth the “UP” mark facing up. (1) PUNCH MARK . ‘Align the end of the holder with tha punch mark on the hance bar, Tighten the upper holder bolt first, than tighten tha lower bolt (2) UP" MARK (1) WIRE BANDS IX Iriatll the wire bands. ay 12-5 aFRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL SMa, | SeRDOME TER caer a REMOVAL False 1he frant Wheel off tne ground, Disconnect the speedometer cable trom the speedometer gear box by temoving the cable set screw. Lowsen the front axle holder Hemove the axle and the front wheel. nore [it you squeeze the front brakes lever after the caliper le r= moved, the caliper piptan will move out and rake assembly difficult INSPECTION © AXLE Set th axle in V blocks and measuire the runout. SERVICE LIMIT: 0.2 mm (0.01 in) Cchack the rim runout by placing the wheal ina truing stand, Spin the wheel slowly and reat! the tunaut using 2 dial indica tor SERVICE LIMITS: Fladial. nanouit: 2.0 men (0.08 in} ‘Axial runout: 2.0 me (0.08 in) nore Thn whrel cannot be repalred and must be replaced witha cended few one if hid service limits are @ 12-6FRONT WHEEL/SUSPENSION/STEERING * WHEEL BEARING Jur the inner race of the asch bearing with your finger. The bearings should tun emaothly and quietly. Also check that the hearing outer rece Tite dghtly in the hub Remove and discard the besrings if the races do not turn smoothly, quietly, orf they Fit loosely jn the hub NOTE Replace hub bearin in pois (1) SPEEDOMETER GEAR BOX DISASSEMBLY Remove the sneadometer gear box dust seat and speedometer gear retainer Fiemove the side coll from the left side (DISC Hemove the hub cover and disc, NOTE heck for dise warpager soo page 14.5. z Cor (a) oust geal a at WHEEL BEARING REPLACEMENT () peanng |) f/ REMoveR vf | Install the bearing remover head and shaft, then femeve the fieve bearings and the distance collar, NOTE Naver reinstall old bearings ance the bearings are removed, they must be repincad with new ones: Toots. Bearing remover head, 16 mm 07746-0050400 ¥ Bearing ramaver shalt 07748 0060100 S (2) BEARING. REMOVER SHAFT 12-7FRONT WHEEL/SUSPENSION/STEERING (2) ATTACHMENT. Divi in a hew right side: bearing first, then install the distance (1) DRIVER celle Driva inva new left sidé boating TooLs: Driver 07749-0019000 Attachment, 32. 35 mi 07748-0010100 Pilot, 15 mmm 07746-0040300 ASSEMBLY Sm == + Do net ger greace on the brake disc or stopping poner will be reduced. (9) SPEEDOMETER GEAR 2) sitims é ; (1) SPEEDOMETER (a) DISTANCE COLLAR GEAR ex (i nISC (6) HUB COVER 11) SPEEDOMETER ss 15 Nem |1.8 kgm, RETAINER d Te / 9) BEARING @ @ (10) BEARING (8) DUST SEAL (7) SIDE COLLAR Install the dust sea, dite and bub cover ~ (2), HUB COVER Tighten the dise mounting batts, TORQUE: 15 Nem (1.5 keem, 11 fb) 12-8FRONT WHEEL/SUSPENSION/STEERING Install the faft side collar Install the’ speedamerer gear retainer in the left side of the ‘wheel hub, aligning its tangs with the slets in the hub, Install the shim, 181 the speadsmeter gear box with groase, and natal the drive gear, (2) SPEEDOMETER, GEAR BOX Install the dust seal and the speedometer gaar box inthe whee! hub, aligning the tangs with the slots 12-9FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL INSTALLATION Fit the caliper over the diss, toking care not Yo damage the brake pads Clean the axle and holder inatall the holeor with the “UP” mark facing upwarde. Install the ane heler suis but do not tighten at this tine. CAUTION Sei the tang on the xearbox unier the stopper on the Teft Fork eg Tinhten the axle-to the spacifiad torque. TORQUE: 65 N-m (6.5 kg-m, 47 Fb) With the front broke applied, pump the fork up and dawn 36 tal times ta seat the axle ond check front brake operation, Tighten the axle holder nuts the uppar nuts frst, then the lower TORQUE: 12 Nim (1.2 kg-m, 9 feb} Gonnect the speedometer cable. Tighten the speedometer cabla set screw FORK REMOVAL Remove the front whol (page 12-6) Remove the front fender and the fork brace, f (2) FORK BRACE 12-10FRONT WHEEL/SUSPENSION/STEERING Remove the brake caliper mouring bolts and the calipar () BOLTS. It the fork ie te be disascembied, loosen the fork cap bolt, but do not camove it yet the fork top end bottom pinch botts and cemdve the tHie fork bridge and stearing stern, Lees tok B (2) SOT TOM FINCH BOLTS Flonove the fork boat clamp and remove ths beot (netaMe (2) 8007 DISASSEMBLY 11) FORK CAP lemove the fork cap carefully + The cap Is under spring pressure. Uxe care when removing it “Seeeienonenennenmeest® land wear eve and Face protection. 12-11FRONT WHEEL/SUSPENSION/STEERING Remove fork spring A. the spring seat and fork-spting B, 41) SPRING & Pour out the fork fluid by pumping the fork tube up and down several timer. (3) SPRING SEAT Hold the fork slider in vise with soit jaws or use a shop towal _ (1) SOCKET BOLT Remove tho sockot bolt with a fiex wrench. ote + Temporarily install the spring and fork bolt if difficulty Is en eountarod in removing the bolt Remove the dist seal and stop ting, a (| DUST SEAL (2) STOP RING up tha fork tube out unt resistence from the sliver bushing f felt. Then maye it in and aux, tapping the bushing lighay anti the fork tube separates from the slider. The slidar bushing ‘ill bo forced out by the fork tube bushingFRONT WHEEL/SUSPENSION/STEERING Flamove the oil lack plece from the piston. (1) OW SEAL Flemove the piston and rebound spring from the fork tub. (2) BACKUP RING . _— (3) SUDER Asie the oll ena, back-up ting and slider bushing from the BUSHING fork the. (4) PISTON nore + Bo nat remove tha foi he bing Unless Ts necosary tevepce thw new one iene pa bustin & S 7 ie (eon uSex prec INSPECTION For ang Measure the fork springs (ree length SERVICE LIMITS: A 74.2 min 2.9208 Bare. Sameer liaaanaaaanwenvevereeernntd Replace aithar spring if Itis shorter than the service limit. Fork tube/stidar Check the fork tube, lidar and piston for score marks, ond ex cessive or abnormal wear Replace any components which sre worn or damaged. Check the fork piston ring for weer or damage, Check the rebound spring for fatigue or damage. ‘Sot the ferk tube in V blocks and read the runout Use 1/2 the total indicator reading to detenmine the actual tun- out ‘SERVICE LIMIT! 0.20 mm (0.008 in} 12-13FRONT WHEEL/SUSPENSION/STEERING Fork tube bushing Visually inspect the slider and fork tube bushing, Replace the bushing if there is excessive scoring or soratching, or it the teflon is wom ea that the copper surface appears on ‘mara than 3/4 of te entira surface. Fisplace the back-up ring distorted. ASSEMBLY Botore assambly, wash all parts with a high flash point or nar flammnabla solvent and wipa them att completely. Cicame (2) L (19) DUST.SEAL (18) STOP RING a (17) OL SEAL as (18) BACK-UP Ang) | |15) SLIDER BUSHING (9) PISTON fae e aceon ae WASHER decane eocr Pico the ail fock place-on tha ond of the piston and incon the: fork tube into the slider PRING A Sa (4) O-RING > (7) SPRING B (10) REBOUND SPRING. (1) OL SEAL (1) BACK-UP RING nea (3) CHECK POINTS (2) BUSHING (3) FORK CAP (5) SPRING SEAT (8) FORK TUBE (8) PISTON RING (11) OW Lock PCE (2 BACK UP ANG , (0) SLDER BUSHING (6) SLIDER BUSHING a Z 5) OL LOCK Pi 12-14FRONT WHEEL/SUSPENSION/STEERING Place the fork sider ine vise with soft jaws or use a shop (1) SOCKET BOUT towel, Apply locking agent to the socket bolt and thread it Into the pistan, Tigiten with an 8 mm hex wrench nore + Tomporaly install fork spring and fork exp oh 19 taht TORQUE: 20 sm (2.0 kg-m, 14 ft Place the slide: bushing over the fork tube ttl itrests on the (1) FORK SEAL slider DRIVER, Ss Lite fotle seal driver, drive th bushing Into place. the back-up ring with the chamfered side Jacing the slider busting Coat the oil seal lip with the recommended fork cil. Drive the oll seal into place using the fork seal driver. ieee, RISES De 11) bust seat 4— |2) STOP RING T (3) OL SEAL (4) BACK-UP RING omres the ork lea and pour Aira etc tbe Ti) COMPRESS FORK LFS TO MEASURE OIL LEVEL SPECIFIED LEVEL: 107 mm (9.2 in - CAPACITY: 412 co(12.9 US 07, 14.5 imp on) Em nw a pr (2) Ol LEVEL 107 mm (4.21n __G) FORK OL 12-15FRONT WHEEL/SUSPENSION/STEERING Now lark spring 8: the tapored end must face toward the bot tom af tha fork tubs = ft = ; Lo] = | (1) PaPERED END (2) DOWN Inotall fork opring ®, the spring seat and fark spring A inta the fork tube (1) FORK SPRING 8 > mh SEAT (2) FORK SPRING A Lodialy install the fork cap wita new Oring (1) FoR CAP Q)ORING Install the fork boot with is breather files toward thin roar. (HOLES: 12-16FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the fork tubo, alloning ite top with the upper surface of the top hrlelge ae shown, 71) UPPER SURFACE Apply oll to the battom pinch bolt and tightan it TORQUE: 33 Nem (3.3 kg-m, 24 feb} Tightan The top pinch bolt TORQUE: 33 Nem (3.3 kg-m, 24 f-tb) Tighten the fork cep. TORQUE: 23 N-m (2.3 kg-m, 17 fet) Push the fork boots up until they just touch the bottom of the 11) STEERING steering stem, then install and tighten the camps, STEM Install the front fonder and the fork brace 1) FORK BRACE Tiahten the front fender/brace mounting bolts. NOTE + Bo not tighten the axle holder nuts, before tightening the front fender/orace mounting nuts. (2) FRONT FENDER 12-17FRONT WHEEL /SUSPENSION/STEERING Install the fallowing: — brake caliper front wheel (page 12-10). NOTE + After tightening the front fender/brace mounting bolts, chten the axis holder nuts, (1) CALIPER STEERING STEM 11) SPEEDOMETER __ (2) METER CABLE REMOVAL Remove the following — handlebar (page 12-9). frart wheel ipage 12-6) — side fairing (page 15-2). — headlight caso nage 19-3) — speedometer cabie and moter ipags 19-4). Remove the faiting bracket Unclamp the ignition ewitch wire by ramoving the scrow: Femove the brake pipe and air guide plate by removing twa bolts {ram the steering 12-18FRONT WHEEL/SUSPENSION/STEERING jemove the steoring stem nut and washer. 2| STEERING Ramioesneason and wash qy sreerna SeaRine ay STEM ADJUSTMENT, Remave the bridge and fork leas. se Remove the steering bearing adjustment nut. Ramovo the dust seal, upper innar race, and upper basting. Pull the steoring stam out of the steering head and remove the lower bearing, (2) Lower BEARING BEARING REPLACEMENT $ NoTE + Always replace the bearing and races as a set. Instaltne stam nut onto the stem to pravent the threads trom being damagad whan tamaving the lower bearing inner race from the ster Remove the lower bearing inner race with a chisel or equiva- lent tool, being careful nat to damage the stem. Remove the dust seal (7) LOWER BEARING —m § / ; ay’ (1) STEERING BEARING { / ADJUSTMENT NUT ) (2) UPPER DUST SEAL : TX (3) UPPER INNER RACE =: . ae SS e——— UPPER BEARING PPPS Se UPPER OUTER RACE (0) Lowen OUTER NACE (0) STEERING STEM 12-19FRONT WHEEL/SUSPENSION/STEERING Install a naw dust seal over the steering stem. (1) STEERING Press a new lower bearing inner race onto the stem. STEM DRIVER i tooLs: i Stearing stem driver 07948~4300101 Femove the uppar and lower bearing outer races with the ball (1) DRIVER. race remover and attachment. HANDLE | TooLs: Ball race remover 07953—MJ10000 — diver attachment 07953—MJ10100 — eriver handle 07963—MJ10200 ‘ (2) DRIVER é ATTACHMENT « Drive new upper and lower bearing outer races into the steer- ing head pipe Toous: z Upper bearing outer raco: Driver 077490010000 Attachment, 42 x47 mm 077460010300 (2) ATTACHMENT @ Lower heating outer race! (2) DaIVER (1) ATTACHMENT Diivor 077490010000 f Attachment, 42.47 mm 077460010300 12-20FRONT WHEEL/SUSPENSION/STEERING |+<——"1) DUST SEAL (2) INNER RACE (3) UPPER BEARING STEERING STEM INSTALLATION Pack the bearing cavities with crease Install the lower boaring onto the stem, Iiisert the stern into the steering head pipe and install the upper boaring, inner ace, dust seal and stearing bearing adjustment ut ‘Temporarily tightan the stesring bearing adjustment nut to the specified torque: FORQUE: 25 Nem (2.9 kgrm, 18 Feb) TOOL: (1) STEERING ‘Steering stem socket 07916—KAs0100 STEM SOCKET. ae Turn the steering stem lack-to-lock four or five times to seat the bearings. Retighten the adjustment nut to the specified torque. TORQUE: 5 Nem (0.5 kgm, 4 ft-lb} Install the fork bridge, washer and stem nut. Temporarily install the fork legs and tighten the stem nut. TORQUE: 118 Nem{11.8 kgm, 85 fb) Install she fark tubes correctly page 12-17) 12-21FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL/SUSPENSION/STEERING Install the fairing brackor Clamp the ignition switch Install the brake pipe amd air guide plate, Tighten the bolts securaly Install the speedometer and headlight case, then connect the speadometer cablo and electrical wire connectors. snd wire. Install the front falring (page 16-21, front wheel (page 12-10) and handlebar Moasura the tearing haad bearing preload 12-22FRONT WHEEL/SUSPENSION/STEERING STEERING HEAD BEARING PRELOAD Placa a stand under the engine and raise the front wheel off the ground. Position the steering Hook a pring blanc: ing head boating preload, em to the straight aheid postion 10 the fork tube and measure the ewer- NoTe + Make-sure that there is.no cable or wire hamess interfer The preload should te within 1.11.7 kp (2.43.7 Ib for right and left turn, IW the readings do not fell within the limits, lower the front wheel on the ground end adjust the stesting bering adust ment nut. 12-23