The following procedure applies to both of the front fork legs.
WARNING
|
NOTE:
When assembling the front fork leg, be sure to replace the following parts:
Before assembling the front fork leg, make sure all of the components are clean.
1. Install:
CAUTION: Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. |
2. Lubricate:
3. Tighten:
NOTE:
While holding the damper rod with the damper
rod holder "2" and T-handle "3", tighten the
damper rod bolt.
4. Install:
5. Install:
CAUTION: Make sure the numbered side of the oil seal faces up. |
NOTE:
6. Install:
NOTE:
Adjust the oil seal clip so that it fits into the outer tube's groove.
7. Install:
8. Fill:
CAUTION:
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9. After filling the front fork leg, slowly stroke the inner tube "1" up and down (at least ten times) to distribute the fork oil.
NOTE:
Be sure to stroke the inner tube slowly because the fork oil may spurt out.
10.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual air.
11.Measure:
Front fork leg oil level "a"
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
Out of specification Correct.
12.Install:
NOTE:
Install the spring with the smaller pitch "a" facing
up.
13.Install:
NOTE:
Checking the radiator fan motor
1. Check:
Radiator fan motor
Faulty/rough movement → Replace.
a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
Positive tester probe →
blue "1"
Negative tester probe →
black "2"
c. Measure ...
Installing the relay arm
1. Lubricate:
Spacers
Bearings
Oil seals
Bolts (unthreaded shaft portion only)
2. Install:
Bearing "1"
(to the relay arm)
Oil seal "2"
(to the relay arm)
3. Rear shock absorber assembly
4. Relay arm
5. Connecting arm
A. Left side
B. Right side ...
Checking the front brake caliper
1. Check:
Brake caliper pistons "1"
Rust/scratches/wear Replace the
brake
caliper assembly.
Brake caliper body "2"
Cracks/damage Replace the brake
caliper
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with
compressed air.
...