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    25 views24 pages

    13 PDF

    Uploaded by

    Erik Varas

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    aia ae | |13 | REAR WHEEL/BRAKE/ SUSPENSION ROUE ARRIERE/FREIN/SUSPENSIO SUSPENSION HINTERRAD/BREMSE/AUFHANGUNG 13-0 REAR WHEEL/BRAKE/SUSPENSION 65 Nem (6.5 kgm, 47 feb) 108 hm (10.8 xem \ ei { 105 Nem (10.5 kgen, 76 felb) 96 Nem (9.8 kg-m, 69 Felb) 13-0 REAR WHEEL/BRAKE/SUSPENSION | SERVICE INFORMATION 43-1 BRAKE PEDAL 13-11 TROUBLESHOOTING 13-2 SHOCK ABSORBER 13-13 REAR WHEEL 13-3 SHOCK LINKAGE 1317 |_REAR BRAKE 13-9 SWINGARM 13.19 SERVICE INFORMATION GENERAL ‘© Support the motorcycle using a hoist or a jack under the engine. © Ucelonly genuine Honda replacement festeners for the rear cuspension. Note the installation direction of the bolts _ The rear shock absorber contains niroren under high pressure. Do rot allow fie or Neat near the shock absorber. Inhaled asbevins fibers have been found to cause respiratory disease and cancer, Never use an air hose or dry brush ro clean brake assemblies. SPECIFICATIONS ew STANDARD SeRVELMAT ‘ear wheel runout | Pediat 2.0 mm 10.08 in) aia 20mm (0 08ini Teaco rwout = ©.2 10.01 Fear bake OLD To ni. 081 1mm @a7inn | Teer rok ning abinwos £0 mn 10.16in) a Cal Shock abeoiiey spa tne Bh 756.8 mm (7.36% tea mm 7.2810 Thar pens temps! carpreeston TeWgW7Gbbe | 188s 80.26 ws | TORQUE VALUES Rear axle 95 Nem (9.5 kg-m, GE ft-lb) Shock absorber mounting bolt (Lower! 45 Nem (4.5 kg-m, 33 ft1D) (Upper) 65 Nem (6.5 kgrm, 47 ft} Swingerm pivet bolt 90 Nem (9.0 ka-m, 66 ft-lb) Shock link-to- swingarm bolt 105 Nem (10.5 kam, 76 frlb) Shock link-ta-shoek arm bolt 105 Nem (10.5 ka-m, 76 ft-Ib} Shock link-to-frame bolt 105 Nem (10.5 ka-m. 76 ft-lb} 13-1 REAR WHEEL/BRAKE/SUSPENSION — TOOLS Special Shock absorber compressor ettechmant Remover shaft Needle bearing remover Common Driver Arachment, 32 x 35 mm Pilot, 20 mm ‘Attachment, 24 x 26 mm Pilot, 17 mm ‘Shick absorber compressor = screw assembly ‘Attachment, 42 x 47. mm Attachment, 37 x 40. mm Retainer wrench body Retainer wrench B Bearing remover head, 17 mm. Bearing remover shaft Pilot, 22 mm. Pilot, 15 mm TROUBLESHOOTING Wonble or vibration in motorcycle + Bent rim + Loose wheel bearing(s! + Loose or bent spokes Damaged tire Axle not tightened properly ‘Swingarm pivot bearing worn + Chain adjusters not adjusted equally + Bent frame or siwngarm Soft auspansion Wook spring 079591610000 (07946~M00100 07931—MA70000 077490010000 07746-0010100 077480040500 07746—0010700 077460040400 (07GME 0010000 (07GME—0010100 077480010300 07746—0010200 07710—0010401 07710-0010200 077460050500 07746—0050100 077460041000 07746~0040300 Hard suspension + Bent shack ebsorber rod + Swingarm pivot bearings damaged. + Bent frame or swingarm ‘Suspension noise + Faulty rear damper + Loose fasteners Poor brake performance + Improper brake adjustment + Worn brake shoes + Brake linings oily, greasy or dirty + Worn brake eam Worn brake drum + Brake arm serrations improperly engeged + Brake shoes worn at cam contact area 13-2 REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Raise the rear whsel off the ground using a hoist or other ad jusable support. Remove the adjusting nut from the brake rod and disconect the brake rod from the brake arm. Loosen the rear axte nut Loosen the right and left drive chain adjusting nuts and lock nuts. Move the rear wheel farward and derail the drive chain from the drive sprocket, Remove the rear axle and jhe wheel, then remove the brake pedal Ser ee (1) REAR AXLE». (2) LEFT ove CHAIN NUT cpicisiatie. ADJUSTING NUT. f INSPECTION © AXLE ‘Set the axle in V blacks and read the axle runout with @ dial in dicator SERVICE LIMIT: 0.2 mm (0.01 in) © WHEEL BEARING ‘Turn the Inner race of each bearing with your finger. The bear ing should turn smoothly ard quietly. Also chack that the outer race of, each besring fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or it thay Ft loosely in the hub (page 13-4). Note + Replace hub bearings in pairs U1) WHEEL BEARING 13-3 REAR WHEEL/BRAKE/SUSPENSION © RIM RUNOUT Ghack the rim runout by plecing the whee! on 2 truing otand. Turn the wheel by hand and measure the runout using a dial in dicator SERVICE LIMITS: Radial: 2.0 mm (0.08 in} Axial: 2.0 mm {0.08 in} @ DRIVEN SPROCKET Chock the condition of the final driven sprocket teeth. (11. GooD, Replace the spracket if it is worn or damaged. NoT= + ifthe driven sprocket is worn or damaged, the drive chain and drive spracket must be inspected BEARING REPLACEMENT Rerrave the side collar and cust seal. (2) DUST) SEAL % Remove the ctivan spracket and driven flange together. NOTE T” Do nat separate the sprocket and flange unless one of them needs to be replaced 13-4 oA eT (2) REPLACE REAR WHEEL/BRAKE/SUSPENSION Replace the dampor rubbars if they are damaged or detariorar- Remove the O-ring and the damper rubbers. Remove the snap ring from the driven flange: Flemove the collar ane bearing (page 13-7). (2) BEARING i i ald wc an amo te tet nether’ Dib usta . acer TOOLS: ‘ berahee Wench 07710-co10401 07710-0010200 Drive out the wheel bearings and the collar. NOTE If the bearings ae removed, they must be replaced with Toots: Bearing remover hoad, 17 mm 977460050500 Boaring remover shaft 977460060100 12) BEARING REMOVER HEAD 13-5 REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY (2) DRIVEN FLANGE Sa (3) DUST SEAL (1) DISTANCE COLLAR (5) DRIVEN. SPROCKET (92) BEARING (7) BEARINGS 411) O-RING (10) RETAINER (g) COLLAR Qe to abe couse (3) DAMPER RUBBER Pack the bearing eavitios with grease 11) DRIVER Dive ina new left bearing with the sealed side of the bearing facing out. TOOLS: Driver 07749—0010000 Attachment, 37 x 40 mm 07748-0010200 Pilot, 17 mm. 07746—0040400 Be caraful not to tilt the bearing while driving it into the hub and make sure that its fully seated. Jnetall the distance collar in the hub, then crive in a new right beaiing with #'e oaled side facing out, Se + Grease on the brake drum reduces stopping power. Keep grease off the brake drum. Groase end install the bearing retainer with the retainer wrench and body, Toors: Retainer wranch body 07710-0010401 Retainer wronch B 07710-0010200 13-6 REAR WHEEL/BRAKE/SUSPENSION Ov Stake the retainer as shown, (1) STAKE Install the dampers Flange bearing removal Remove the following: — hub bearing sleeve TooLs: Drive 077490010000 Smears | SUS pricks Grease the flange beating and driva it into the flange hub. TooLs: (2) SLEEVE, Driver 077490010000 ‘$ Attachment, 2 47 mm 977480010300 Pilot, 17 enn, 07748-0040400 Install the snap ring and sleeve. Install the driven sprocket to the flange hub. Tighton the hub nuts, ‘Apply grease to the new O-ring and instal it, then install the final driven flange. 13-7 REAR WHEEL/BRAKE/SUSPENSION ‘Apply a grease to the dust seal lips and install the dust saal in the hub. Install the side collar. Install the brake panel. oe INSTALLATION (1) Stor AND Place the slot an the brake panel over the tang on the swing Install the drive chain over the drive sprocket Install the resr axla and axle nut. Lightly tighton the nut. Install the brako rod to the brake arm with spring, brake orm pin and adjusting nut. (4) BRAKE aE m1 ADJUSTING NUT Adjust tho drive chain slack (page 9-11) and tighten the axle TORQUE: Rear axle nut: 95 Nm (9.5 kg-m, 69 ft-lb) Adjust the reer brake pedal free play (page 3-13). gd AXLENUT ip 13-8 REAR WHEFL/BRAKE/SUSPENSION REAR BRAKE REMOVAL/INSPECTION Remove the roar whoo! (page 13-3), Remove the tear brake panel, + Inhaled asbestos fibers have been found (0 cause respiratory disease and concer. Never use an air hose or dry brush to clean brake assemblies. @ BRAKE DRUM Moasura the drum 1D. SERVICE LIMIT: 111 mm (4.37 in) ¢ BRAKE LINING Check the brake shoe springs for fatigue or damage and check the brake cam for waar of cracks. ‘Measure the brake lining thickness. SERVICE LIMIT: 2.0 mm (0.08 in) DISASSEMBLY Force the brake shoes out and remove them by hand. Femove the brake arm bolt, brake aim and wear indicator (1) Wear INDICATOR (2) BRAKE ARM 13-9 REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY + Greese on the brake Unings reduces stopping power. Keep __ grease off the tings. (a).ouisT, (5) BRAKE ee SEAL CAM (2) WEAR INDICATOR (3) FELT SEAL (6) WASHER, (7) SPRING (1) BRAKE’ARM’ (8) BRAKE SHOE 416) WASHER (9) BRAKE PANEL Inatall the washer onto the braka panel hy aligning the groove with the bose of the brake panel. Apply @ small amount of giease to the brake cam and anchor pin and install he eam in the brake panel REAR WHEEL/BRAKE/SUSPENSION Install the ott seal Install the wear indicator, aligning the indicator inner tab with the brake cam cutout, ‘Align the punch mark on the brake arm with the punch mark an the brake cam, Tighten the brake arm bolt. Install the new brake shoes on the brake panel. Place the brake panel assembly in the whee! Install the rear wheel (page 13-8) BRAKE PEDAL REMOVAL/INSTALLATION Remove the brake adjusting ut and disengege the brake rad from the brake arm, BRAKE ARM. (3) RAKE ARM BOLT (1) SPRINGS (2) BRAKE SHOES 13-11 REAR WHEEL/BRAKE/SUSPENSION Remave tha right foot peg by removing tivo mounting bolts, Romove the brake pedel pinch bolt, then remove the pivot. j (4) REAR BRAKE LIGHT] Remove the cottar pin and digconnect the brake rod fram the SWITCH ROD brake pedal Disconnect the rear brake light awitch red and spring, Apply graase to the pivot and install the removed parts In tho reverse ordar of removal. Adjust the brake pocal tree play |pege 3-13). ipvor Swine nop , oo 5D %, LE e é \ (0) BRAKE ROD, (1) BRAKE PEDAL _ SFRING a 16) BRAKE PEDAL \ Nore + Replace the dust seals with the new ones SEALS whan reassembling. 13-12 REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER ry + The shock absorber contaias nitrogen gas under high pressure. Vo not allow fire or heat near the shock absorber, CSD: Coven Support the motoreyele in an upright postion ond raise the roar wheel off the ground, Romave the seat and side covers {page 15-2) Remove the shock absorber upper mounting bak: (i SHOCK ARM TO SHG Femove the shock link-to-shock arr bolt. LINC BOLT Femova the shock absarber lower mounting balt. iyi (2) SHOCK ABSORBER LOWER MOUNTING BOLT Unhook the shock absorber drsintube, then emove ne shock, SHOGK ABSORAER™ ze absorber. = : : 13-13 REAR WHEEL, DISASSEMBLY (1) SCREW oon + The damper unit is filled with nitrogen gas under high pressure, do not try t0 disassemble i, (2) ATTACHMENT Install the attachment onte the shack absorber compressor Set the shock absarber in the compressor ac shown and com- press the spring approximately 15 mm (0.6 inl Too.s: ‘Attachment 07959—ma10000 (3) SHOCK ABSORBER ‘Shock absorber compressor: O7GME—0010000 COMPRESSOR — screw assembly 07GME—0010100 Remove the ston ring then loosan the compressor scraw and remove the shock absorber upper spring seat. spring, dust ‘eal, lower spring soat and spring guide. (1) STOP RING % INSPECTION Measure the opring free longth SERVICE LIMIT: 184.9 mm (7.28 int Check the spring guide, lower spring seat, dust seal, spring (1) DAMPER UNIT (2) SPRING ‘and upper spring seat for wear or damage. SEAT 43) oust a SEAL ef wbroe A é RING (7) sPaina’ 4 GUIDE U (5) SPRING 16) SPRING. SEAT 13-14 REAR WHEFL/BRAKE/SUSPENSION Visually inspect the damper unit for dents, oil leaks or other faults. Replace the damper unit if necessary. Place the damper rod on a scale and measure the farce ra quired to compress the damper 10 mm (0.4 in| ulate the comprassion fares by subtracting the weight of the shock absorber from the value obtained, If the force ve quired is fess tha 16.5 kg (64 Ibs), gasis leaking. Examine the damper red and raplace the damper unit fit is bent or scored. SHOCK ABSORBER DISPOSAL PROCEDURE WVPLASTIC BAG (2) DRILL BIT Center punch the damper case 10 mark the driling point, ap- proximately 18 mm {1/2 in) from the top surface. Wiap the domper unit inside & plastic bag. Support the damper unit up~ fight ina vise a8 shown. Through the open end of the bag, Insert a drill motor with a sharp 2—3 mm (5/64— 1/8 in} dill bit + Donor use. dull dril bie which could cause a buildup of exces sive heat and pressure inside the damper, leading (0 explosion ui and severe personal injury, (3) DAMPER UNIT + The shock absorber contains nitrogen kas asd ofl under high ©) BANTER CNT pressure. Do ut dri any farther down the damper ease than ‘tke measurement given abaye, or You may drt into the oft chamber; olf escaping under high pressure may cause serious personal injury. +. Always wear eve protection to avoid getting metal shavings in your eyes when the gas pressure is released. The plastic bag és only intended to shield vou from the escaping ras. Hold the bag around the dill motor and briefly run the dil ‘maior Insice the bag: this will inflate the baq with air from the ‘moior and help keep the bag trom gotting caught in the bit when you start (1) stop 7 RING ASSEMBLY Install the spring quie®, tower spring ses Luppar spring seat on the damper, Compress the spring with the compressor. dust seal, spring sna Install the stop ring securaly into the groove in the damper. 13-15 REAR WHEEL/BRAKE/SUSPENSION Loosen the compressor graduslly and align the lower joint groove with the location pin on the spring seat as shown. Remove the compressor and install the drain tubs, (3) DRAIN INSTALLATION Raise the raar wheel Tully and! insert she shock absorber from ‘the boom Align the upper mount with the frame bracket and install the pae’ mounting bolt and nut Tighten the upper mounting bol. ‘TORQUE: 65 Nem (8.5 kg-m, 47 ftb) Align the lower mount with the sheck am and tighten the lower mounting bolt. TORQUE: 45 Nem (4.6 kg-m, 33 ft) Cannact the shock arm-to-shock link and tighten the bolt. TORQUE: 105 Nem (10.5 kg-m, 76 ft1b} me (2) SHOCK ARM-TO: SHOCK LINK BOLT Install the shock absorber drain tube as shown, (1) DRAIN, TUBE 13-16 REAR WHEEL/BRAKE/SUSPENSION SHOCK LINKAGE REMOVAL, Raise the rear wheel off the ground with @ workstand oF box Homove the folowing: — shock arm-to-shock link bolt and rut — rear shock absorber lower mounting bolt. shoee link from the swinggem. — chain sliner mounting bolt and chain shack orm bolt, nut, and ramove frame. Check the shock arm, shock link dust seals and pivot collars for wear or damage. BEARING REPLACEMENT ® Shack arm Prass aut the shock arm bearings using the following tools. Toots: Driver 07749—-0010000 Pilot, 20 mm 077480040500 Pilot, 22 erm. 077480041000 13-17 LOWER MOUNTING BOLT! a Bt ) 8 o & @ % 2@ Cag? ® (SHOCK ARM me DRIVER REAR WHEEL/BRAKE/SUSPENSION Pack new needle bearings with grease. 7 Carefully press tha neadie bearing into the shack arm with the (1) DRIVER dannii jon marks facing out. Toots: Driver 077490010000 (2) ATTACHMENT Axtachment, 24 x 26 mm 07746—0010700 Pilot, 17 mm. 07746—-0040400 Pilot, 15 mm. 077460040300 © Shoele tink be Removal (1) DRIVER ‘Toots: (2) ATTACHMENT Driver 07749—-0010000 (3) BEARING Pilot, 22 mm 077460041000 (4) SHOCK LINK atoms Installation: TooLs: Driver 077490010000 Attachment. 24 x 26 mm 077460010700 Pilot, 17 mm 077460040400 INSTALLATION Install the shock link with the pivot colar onte the swingarm. Install the shock arm onto the frame. 2128 ABSORBER LOWER! MOUNTIN Tiahten the shock tink-to-swingarm bolt fay Shock uni SWINGARM BOLT TORQUE: 105 Nem (10.5 kg-m, 76 ft-4b) ei Tighten the shock arm-to-trame bolt TORQUE: 105 Nim (10.5 kg-m, 76 f-1b) Tighten the shack absoiber lower mounting bolt. TORQUE: 45 Nem (2.5 kg-m, 33 ft-lb) ['3) SHOCK ARM-TO-FRAME \_ BOLT 13-18 REAR WHEEL/BRAKE/SUSPENSION Connoct the chock link to-shock arm and tighten tho bolt. TORQUE: 105 Nim (10.5 kgm, 76 fe-tb} SWINGARM REMOVAL Remove the following ~ rear wheel (page 13-2) — drive chain cover. Remove the shock arm-to-shock link bolt, Remove the rear shack absorber lawer mounting bok. (2) SHOCK APM-TO SHOCK LINK BOLT. Remove the swingarm pivat bolt caps. Remove the right and left swingarm pivots, then remove the swingarm, 7 SWINGARM PIVOT BOLT 13-19 REAR WHEEL/BRAKE/SUSPENSION omove the crive chain slider and chain guide. (1) CHAIN GUIDE Cheok the drive chain sider and chain guide for wear or ~ damage and replace thom if necessary. (2) Drive CHAIN SLIDER INSPECTION (1) DUST SEAL (2) NEEDLE BEARING: Inspect the dust seals, needle bearings and collar. é Replace them if they Nave score marks, scratches, excessive fr abnormal wear. PIVOT BEARING REPLACEMENT Femove the side bushings, Femove the needle bearing with the needle bearing remover. Toots: Needle hearing remover 07931—MA70000 (1) NEEDLE BEARING REMOVER 13-20 REAR WHEEL/BRAKE/SUSPENSION Apnly grease to the needa bearings dust seal lips and cota. (1) DUST SEAL (2) SIDE Ss (9) COLLAR ING Be Bus!

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