ANUAL SERVICE M

ROD GUIDE CASE INSPECTION

Inspect the rebound rubber and dust seal lips for wear or damage and replace the rod guide case with a new one if necessary.

Visually inspect the rod guide case metal.

If the metal is worn so that the copper surface appears, replace the rod guide case with a new one.

Remove the O-ring from the rod guide case and replace it with a new one.

DAMPER ROD INSPECTION

Inspect the damper rod sliding surface for damage or distortion.

DAMPER ASSEMBLY

Before assembly, wash all parts with solvent and blow them dry with compressed air.

Make sure there is no dust or lint on any of the parts.

NOTICE

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Never assemble valves which might have gotten dusty or otherwise contaminated during the dis­assembly process. Disassemble them, thor­oughly clean them with solvent and blow them dry with compressed air before assembly.

• Use care to avoid getting solvent on the piston ring and O-ring.

• The valve arrangement and number of valves may differ from those shown.

Apply shock oil to a new O-ring, and install it to the rod guide case.

Install the special tool onto the damper rod.

TOOL:

Slider guide, 16 mm 07PMG-KZ40100

not available in U. S.A.

Carefully install the rod guide case with the rebound rubber facing up, over the damper rod.

Remove the special tool.

Install the valve stopper and compression valves onto the damper rod.

COMPRESSION VALVES

Install the piston onto the damper rod.

Install the rebound valves with their polished sur­faces facing down.

NOTICE

Be careful not to bind the valves when installing the piston onto the damper rod. Also, check that they are concentric with the damper rod.

Install the valve stopper.

Stake the end of the damper rod in three places as shown, to the end nut.

Coat the damper rod with Pro Honda HP Fork Oil 5W or equivalent. Check the rod guide case by sliding it up and down fully to be sure there is no restriction.

Coat the damper case inner surface, piston ring and O-ring with Pro Honda HP Fork Oil 5W or equivalent, and insert the damper rod assembly carefully.

Install the stopper ring into the groove in the damper case.

After assembling, check that the stopper ring is seated in the groove of the damper case completely. You should not be able to pull the damper rod out of the damper case.

Set the shock absorber in a vise with a piece of wood or soft jaws to avoid damage.

NOTICE

Do not over-tighten the vise and distort the damper case.

Drive the end plate squarely and evenly into the damper case with a plastic hammer.

Fill the damper case and reservoir with recom­mended shock oil through the damping adjuster hole.

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent STANDARD OIL CAPACITY:

395 cm3 (13.4 US oz, 13.9 Imp oz)

Slowly pump the damper rod until there are no bub­bles in the oil that overflows from the damper case.

Remove the damper unit from the vise.

Position the damper unit so the damping adjuster hole faces up. Turn the damper unit as shown to bleed any air from the reservoir completely.

• When bleeding air from the reservoir, be careful to hold the damper at the angles shown so the filler hole points up.

Temporarily charge the reservoir with 49 kPa (0.5 kgf/cmJ, 7.1 psi) of air slowly to inflate the bladder.

Check for any oil that may leak out of the valve while pressurizing. Replenish oil as necessary.

Fill the damper with recommended shock oil to the damping adjuster hole neck.

Apply oil to new O-rings and install them to the damping adjuster.

Dip the damping adjuster in clean shock oil.

Slowly install the damping adjuster.

Tighten the damping adjuster to the specified torque.

TORQUE: 29 N m (3.0 kgf m, 21 lbf-ft)

Wipe off all oil from the damper rod; oil left on the damper rod can lead to premature failure of the oil seal.

Check the oil leaks.

Stake the damping adjuster as shown.

Release the air that was in the reservoir at precom­pression. Fill the reservoir with 980 kpa (10.0 kgf/ cm2,142 psi) of nitrogen gas.

ACAUTION

The shock absorber is fitted with a gas-filled reservoir. Use only nitrogen gas to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion resulting in seri­ous injury.

Install the valve cap.

Install the spring with its tapered end facing down. Install the spring seat and stopper ring.

Loosely tighten the adjusting nut and lock nut.

Turn the shock absorber lower mount so the rebound adjuster screw is on the same side of the shock reservoir.

Turn the spring adjusting nut until the spring length measurement recorded at disassembly is reached or until the spring length is as specified below.

STANDARD SPRING LENGTH:

'05-'07: 258.5 mm (10.18 in)

After '07: 258.0 mm (10.16 in)

Hold the adjusting nut and tighten the lock nut.

TORQUE: 44 N m (4.5 kgf m, 32 Ibf ft)

Use this standard spring length as the baseline.

See the Owner's Manual for detailed instructions on adjusting preload and damping for riding conditions and rider skill.