HPSD (Honda Progressive Steering Damper): After ’07
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Clean and apply a locking agent to the steering damper mounting bolts.
Install the steering Install the steering damper, collars and bolts.
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• The upper side collar is shorter than the lower side collar. • Check that the stopper ring side of the damper rod is facing toward the front. Tighten the steering damper bolts to the specified torque. TORQUE: 20 N-m (2.0 kgf m, 15 Ibf-ft) |
clamper onto the steering head pipe with its "UP" mark facing up and facing toward the front.
Raise the front wheel off the ground by placing a workstand or equivalent under the engine.
Check that the steering moves smoothly from side- to-side.
Install the front visor (page 3-5).
Remove the steering damper (page 14-38).
Visually inspect the steering damper for wear or damage.
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Check the following:
- Damper case for deformation or oil leakage
- Damper rod for bending or damage
Replace the damper case or damper rod if necessary.
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Measure the damper rod length with the 'inside' jaws of a vernier caliper. |
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SPHERICAL BEARING |
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DAMPER ROD |
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Fully extend and compress the damper rod by hand. Release the damper rod then check that it extends to its maximum length.
STANDARD (maximum length):
117.55 - 118.35 mm (4.628 - 4.659 in)
Check the damper rod for smooth operation.
If the damper rod operation is not smooth, check the damper rod for bends or damage.
If the damper rod does not extend to maximum, disassemble the steering damper (page 14-40).
Check the spherical bearings for wear or damage. Move the spherical bearing with your finger. The spherical bearing should move smoothly and quietly.
Replace the spherical bearing if it does not move smoothly or quietly.
Install the steering damper (page 14-38).
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SPHERICAL BEARING
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Remove the steering damper (page 14-38).
Remove the stopper ring.
Press the spherical bearing out of the damper mounts.
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Press a new spherical bearing into the damper mounts using the special tool.
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Drive the bearing in evenly; do not allow it to tilt. |
TOOL:
Collar 07KPF-VD60100
Install a new stopper ring into the groove of the damper mounts securely.
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Set a 7 mm bolt and nut to the spherical bearing as shown.
Measure the stabled rotation torque of the spherical bearing inner by rotating the bolt.
STANDARD: 0.04 Nm (0.004 kgf m. 0.03 Ibf ft) max.
Install the steering damper (page 14-38).
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END CAP/O-RING |
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Record the damping force adjuster position. |
Remove the steering damper (page 14-38).
Clean the damper assembly thoroughly.
Install a 4 mm screw to the end cap.
Remove the snap ring while pushing the end cap, and then remove the end cap and O-ring.
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RETURN SPRING |
Remove the washers and return spring from the damper case.
Install a 8 mm screw to the free piston, then remove the free piston and O-ring.
Drain the damper oil from the damper case.
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Remove the plug bolt and O-ring.
O-RING
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PLUG BOLT
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Remove the adjuster piece from the damper case.
ADJUSTER PIECE
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Always replace the damper rod assembly with a new one. |
Remove the dust seal.
Remove the snap ring from the damper case groove.
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DUST SEAL |
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SNAP RING |
Remove the damper rod assembly out of the damper case.
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DAMPER CASE
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Check the damper case inner surface for abnormal scratches.
Replace the damper case if necessary.
DAMPER ROD ASSEMBLY
NOTE:
• When assembling the steering damper, follow the procedures below.
• Clean the inner surface of the damper case thoroughly.
• Bleed the air completely in oil.
• Always replace the damper rod as an assembly with a new one.
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ADJUSTER PIECE |
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O-RING |
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DAMPER CASE |
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& O-RING |
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DAMPER ROD ASSEMBLY |
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О o-ring end cap |
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SNAP RING |
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Si! PLUG BOLT DAMPER PISTON |
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O-RING SNAP RING DUST SEAL |
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RETURN SPRING |
Check that the Pour recommended damper oil into a suitable con - damperoil tainer until the steering damper is fully submerged. temperature is 20°С <68°F). RECOMMENDED DAMPER OIL:
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Pro-Honda HP Fork Oil 5W or equivalent
• Check the damper oil for contamination.
• Do not allow foreign materials to enter the damper oil.
Submerge the damper case into the oil.
Submerge the damper rod into the oil.
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Bleed any trapped air at the O-ring seating surface by turning the O-ring. |
Shake a new damper rod assembly until there are no air bubbles.
• Be careful not to damage the damper rod and damper piston, especially around the damper rod sliding surface.
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Bleed any air out from the damper case and damper
piston following the procedure below:
1. Install the damper piston into the damper case, pump the damper rod quickly.
NOTE.
• To open the piston valve, pump the piston rod quickly.
2. Remove the damper piston from the damper case.
3. Bring any air out from the damper case by using your finger as shown.
4. Repeat steps 1 to 3 until there are no air bubbles in the damper case and damper piston 3 times for complete air bleeding.
Install the damper rod into the damper case carefully.
Install the snap ring to the damper case groove.
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Keep the damper case submerged in oil. |
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SNAP RING |
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In oil: |
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FREE PISTON |
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lnoil: DUST SEAL |
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O-RING C$5* |
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Fully seated: |
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• Be careful not to damage or deform the snap ring.
• Be certain the snap ring is firmly seated in the groove.
Install the dust seal to the damper case until it is flush with the damper case surface.
Fully extend the damper rod.
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Bleed any trapped air at the O-ring seating surface by turning the O-ring. |
Install a new O-ring to the free piston.
Install and push the free piston fully into the damper case while holding the damper rod at maximum length.
• Check that the free piston is fully seated to the damper case.
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Keep the damper assembly submerged in oil. |
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In oil: |
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ADJUSTER PIECE |
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O-RING |
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-► : OIL FLOW |
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In oil: |
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PLUG BOLT |
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Bleed any trapped air at the O-ring seating surface by turning the O-ring. Make sure the adjuster knob moves freely before tightening the plug bolt. |
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Install and tighten the plug bolt securely. NOTE: Oil is displaced as the adjuster piece and plug bolt are installed into the damper case. The displaced oil causes the free piston to move slightly as shown in the illustration. |
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Check that the damper rod is fully extended to its maximum length. Install a new O-ring to the plug bolt. |
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Install the adjuster piece into the threads of the damper case and thread it one turn. |
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07AMJ-MENA100 |
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Remove the steering damper from the oil. Drain the damper oil from the sub tank. Gauge the depth between the spring seating surface of the free piston and surface of the damper case using the special tool as shown. |
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COLLAR |
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SHOULDERED END |
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PROBE |
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(In) 1.14 |
(mm) Г 29 |
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1.12 |
• 28.5 |
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1.10 |
- 28 |
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1.08 |
- 27.5 |
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1.06 |
- 27 |
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104 |
- 265 |
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102 |
■ 26 |
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1.00 |
L 25.5 |
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Max. Standard |
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20 |
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40 |
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60 CC) |
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Before using the tool, make sure that the shouldered end of the probe is extending from the collar side of the depth gauge. Insert the collar of the depth gauge into the sub tank. Loosen the thumb screw and lower the shouldered end of the probe until it stops. I Tighten the thumb screw and remove the tool. Measure the depth of the free piston with a caliper by measuring the distance between the end of the probe and the collar. STANDARD: 27.3 - 27.9 mm (1.07 - 1.10 in) at oil temperature 20°С (68°F) Measure the oil temperature. If measured temperature is other than 20° С (68° F), refer to the oil chart (page 14-45). If the measured depth is other than the standard length, disassemble the steering damper and start over. The depth of the free piston will change according to the oil temperature as shown. |
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unit: mm (in)
TOOL: Depth gauge |
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l_ |
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32 |
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140CF) |
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Out of oil |
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4 mm SCREW |
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END CAP |
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Be certain the snap ring is firmly seated in the groove. |
Thread a 4 mm screw to the end cap and install a new snap ring to the damper case while pushing the end cap until the snap ring groove appears.
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Out of oil: |
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DAMPER ROD |
Check the operation of the damper rod, pump it slowly, extend or compressed by hand.
Check the following:
- Oil leakage
- Abnormal noise by trapped air
If you hear abnormal noise by trapped air, reassemble the steering damper.
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Measure the damper rod length with the 'inside' jaws of a vernier caliper. |
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Out of oil:
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Measure the length between the spherical bearings as shown:
STANDARD:
Fully compressed damper rod length:
93.55 - 94.35 mm (3.683 - 3.715 in)
Fully extended damper rod length:
117.55 - 118.35 mm (4.628 - 4.659 in)
If the measured lengths are outside the standard length, disassemble the steering damper and start over.
NOTE:
The normal operation of the HPSD can not be secured when the fully compressed damper rod length is more than standard.
Return the damping force adjuster to its original position.
STANDARD POSITION:
9 clicks out from full in
Install the steering damper (page 14-38).
