ANUAL SERVICE M

FRONT WHEEL

REMOVAL

Remove the bolts and brake disc cover.

BOLTS

Raise the front wheel off the ground by placing a workstand or equivalent under the engine.

Remove the axle nut and loosen the left axle holder bolts.

AXLE NUT

AXLE

INSPECTION

AXLE

Set the axle on V-blocks and measure the runout. Turn the axle and measure the runout using a dial indicator.

Actual runout is 1/2 of the total indicator reading. SERVICE UMIT: 0.20 mm (0.008 in)

WHEEL BEARING

Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly.

Also check that the bearing outer race fits tightly in the hub.

Replace the bearings if the inner race does not turn smoothly, quietly, or if outer race fits loosely in the hub.

WHEEL RIM

Check the rim runout by placing the wheel in a truing stand.

Spin the wheel by hand, and read the runout using a dial indicator.

Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Check the spokes and tighten any that are loose.

DISASSEMBLY

Remove the tripmeter gear box.

Remove the left side collar and dust seal.

Remove the brake disc bolts and nuts. Remove the brake disc.

Replace the wheel Install the remover head into the bearing. bearings m pairs. From the opposite side of the wheel, install the Do not reuse old remover shaft and drive the bearing out of the bearings, wheel hub.

Remove the distance collar and drive out the other bearing.

TOOLS:

Bearing remover head, 20 mm Bearing remover shaft

BEARING REMOVER HEAD

ASSEMBLY

16 N m (1.6 kgf-m, 12 Ibf-ft) TRIPMETER GEAR BOX

Place the hub in the center of the rim, and begin the lacing with new spokes.

Adjust the hub position so the distance from the hub left end surface to the side of the rim is 28.0 ±

1. mm (1.10 ± 0.04 in) as shown.

Torque the front spokes in two or three progressive

steps

TOOL:

Spoke wrench, 6.1 mm 07JMA-MR60100

or 07701-0020300 (6.1 mm) or equiv­alent commer­cially available in U. S.A.

TORQUE: 3.68 N m (0.4 kgf-m, 2.7 lbf-ft)

Install the front rim lock, setting rubber, tube and tire.

Tighten the front rim lock to the specified torque. TORQUE: 12 N m (1.2 kgf m, 9 Ibf ft)

Pack all bearing cavities with grease.

Drive the left wheel bearing in the wheel hub until it is fully seated using special tools.

• Install the wheel bearings with the sealed sides toward the outside.

TOOLS:

Driver 07749-0010000

Attachment, 37 x 40 mm 07746-0010200

Pilot, 20 mm 07746-0040500

Install the distance collar into place, then drive the right wheel bearing using the same special tools.

Install the brake disc onto the wheel hub with the drive mark facing out.

Install the brake disc bolts and nuts.

Tighten the nuts to the specified torque.

TORQUE: 16 Nm (1.6 kgf m, 12 Ibf ft)

Pack a new left dust seal lip with grease and install it into the hub.

Check the left side collar and tripmeter gear box for wear or damage.

Pack the tripmeter gear box and dust seal lip with grease.

Install the left side collar to the wheel.

Install the gear box while aligning the trip meter gear tabs of the gear box with the grooves on wheel.

INSTALLATION

Clean the clamping surface of the axle and axle holders.

Install the front wheel between the fork legs while inserting the disc between the pads, and align the tab of the tripmeter gear as shown.

Check that the tripmeter gear box O-ring is in good condition, replace it if necessary.

Apply thin layer of grease to the axle and insert the axle from the right side.

Install and tighten the front axle nut to the specified torque.

TORQUE: 88 Nm (9.0 kgf m, 65 Ibf ft)

Tighten the left axle holder bolts to the specified torque.

TORQUE: 20 N-m (2.0 kgf m, 15 Ibf-ft)

With the front brake applied, pump the front sus­pension up and down several times to seat the axle and check the front brake operation.

BOLTS 7

FORK

REMOVAL

NOTE:

When removing the both fork legs, remove the steering damper to prevent damaging it (page 14­38).

Remove the following:

- Front visor ('05 - '07: page 3-5, After '07: page 3­6)

- Front wheel (page 14-8)

Remove the mounting bolts and front brake caliper.

Do not operate the brake lever after removing the caliper and front wheel. To do so will cause diffi­culty in fitting the brake disc between the brake pad. Remove the bolts and brake hose clamp.

Remove the screws and tripmeter cable clamp.

Remove the bolts and fork protector.

Loosen the fork top bridge pinch bolts.

When the fork is ready to be disassembled, remove the handlebar and holders (page 14-32) and loosen the fork damper using the following procedure.

When disassembling the fork leg, turn the rebound and compression adjusters counterclockwise to the softest position to prevent damaging the adjust­ment needle (be sure to record the number of turns from the starting position).

Loosen the fork damper using the special tool, but do not remove it yet.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

Loosen the fork bottom bridge pinch bolts and pull the fork leg down and out.

DISASSEMBLY

Clean the fork assembly, the sliding surface of the fork slider and the bottom of the slider around the center bolt before disassembling the fork.

Measure the length between the axle holder and outer tube, and record it before disassembling the fork.

Hold the outer tube and remove the fork damper using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

Slide the outer tube down onto the axle holder.

Drain the fork oil from the fork leg.

Drain the fork oil from the oil hole (After '07: oil holes) in the fork damper.

Temporarily install the fork damper assembly into

the outer tube. FORK DAMPER ASSEMBLY

Set the axle holder of the slider in a vise with a piece of wood or soft jaws to avoid damage.

Loosen the center bolt.

Push the fork damper out from the slider until the lock nut is fully exposed and install the piston base or mechanic's stopper tool between the axle holder and lock nut.

TOOL:

Piston base 07958-2500001 or

Fork rod stopper 07AMB-KZ3A100

(U. S.A. only)

Make the mechanic's stopper tool from a thin piece of steel (1.0 mm thick) as shown if you do not have a special tool.

Hold the lock nut and remove the fork center bolt from the fork damper.

Remove the push rod from the piston rod.

Remove the piston base or mechanic's stopper tool while pushing the fork cap.

PISTON BASE

Remove the fork damper assembly from the fork assembly.

Remove the fork assembly from the vise.

Remove the fork spring from the fork assembly.