FRONT WHELL/SUSPENSION/STEERING 24 Nem (2.4 kgm, 17 Feld) 100 Nem (19.9 kgm, 72 Feb) 28 Nem {2.8 kg-m, 20 feb) 33 Nem {3.3 kg-m, 24 feb) 65 Nun 16.5 kgm, 47 telby 32.Nem (1.2 kgm, 9 feb) 27 Nem (2.7 kgm, 20 Feb12, FRONT WHEEL/SUSPENSION/STEERING ‘SERVICE INFORMATION 12-1 FRONT WHEEL 125 TROUBLESHOOTING 12-2 FORK 12-40 HANDLEBARS 12-3. STEERING STEM 1247 SERVICE INFROMATION GENERAL © A box or work stand is required to support the motorcyle. iN Brake dust may contain asbestos. + Inkailed asbestos fibers have been found 10 cause respiratory disease and cancer. Never use an cir hose or dry brush (a clean brake assemblies. + In the United States, ust an OSHA approved vacuum cleaner or eternate method approved by OSHA designed to minimice the hazard caused by airborne asbestos fibers. SPECIFICATIONS vera ‘STANDARD SERVICE LIMIT ‘Axle runout Front wheel rim runout — 0.2 mm 10.0% in) Radial — 2.0 mm 10.08 in) Axial — 2.0 mm (0.08 in) Fork spring free length Fork tube runout 999.3 mm (23.59 in| 893.3 mm [23.36 In) — 0.2 mm (0.01 in) Front fork oil capacity 592 cc (20.0 US oz, 20.8 Imp 02) = Fork oil level 120 rn (4.7 in) — TORQUE VALUES Handiotare upper holder Handletars lower holder Front hub cover screw Brake disc bok Front axle Front axle holder nut Fork slider socket bolt Lower fork pinch bolt Fork cao bolt Upper fork pinch bolt Brake calizer bracket bolt Steering adjustment nut Steering stem nut TOOLS Special Fork seal driver Fork seal driver attachment Steoring stem socket Stearing stom driver Boll race remover Ball race remover attachment = Driver handle Adjustable pin spanner Stoorng booring attachmart 24 Nem (2.4 kgm, 17 Fell) 26 Nem (2.4 kgom, 17 feb) 1.5 Nem (0.15 kgm, 1.1 ft-lb) 15 Nem (1.5 kgom, 11 feb) 56 Nem (6.5 kgm, 47 feb) 12 Nem (1.2 kgran, 9 feeb) 20 Nem {2.0 kg-m, 14 ft-lb) Apply locking agent to the threads 33 Nem {3.3 ko-m, 24 feb) 23 Nem (2.3 gyn, 17 Ftlb) 24 Nem (2.4 kgm, 17 fttbh 26 Nem {2.5 kgm, 18 [Clb 5 Nem 10.5 kg-m, 3.6 fb) 100 N-m {10.0 kg-m, 72 fib) 97947—KA5O100 97947—«FO0100 07916—KA50100 97946—4300101 or 07946—Msco000 97953—MJ10000 or 07853—MJI000A (U.S.A, only) 07953—MJ10100 97953—MJ10200 077020020001 GN HTS4 {U.S.8. only) 12-1FRONT WHELL/SUSPENSION/STEERING Common Bearing remover head, 15mm 07746-08040 Bering remover shaft 0774600501002" sa valent commercaly Driver 077480010000 *vallable in U.S. ‘tachment, 92 «36 mm 077460010109 Pict, 19 mir 077460049300 Look nut merch, 80 x 32 mm 077160920409. Extension bar 07716 -o020500-1 9% eauvatent commercially Attachment, 42 x 47 mm 977460010300 Svallat “ Hard Stosing + "Storing scfustment to tight + Faulty steering stem bearings + Insufficient air in front tire ‘Staars to One Side ot Does Not Track Straight Bent fork + Bent front axle, whee! installed Incorrectly + Unequal oil quantity in fork tubes Front Whee! Web! + Distorted rim Worn front whee! bearings Loose or broken spckes Faulty tire Asle or axle holder not tightened properly Soft Suspansion + Weak fork springs + Insufficient fluid in fork leas Hard Suspension + Fork all level too nigh + Fork tubets) bent or fork siideris} damaged Front Sueponsion Noioe + Fork slider binding + Insuffient fluid in fork legs + Loss fork fasteners 12-2FRONT WHEEL/SUSPENSION/STEERING HANDLEBARS (1) LETHANDLEBARS (2) MASTEN SWITCH CYLINDER ) REMovaL : aE (3) THROTTLE Femave the following parts: eRe — Wire bands = Left handlabars ewitch Clutch/choko lover ho'dor — Front brake master cylinder ) —Sotorengne sey saan — Throttle grip (6) CLUTCH CHOKE LEVER 314) STARTER! remove to upper hls sn hadobr ESI on Remove the lower holders it necessary. INSTALLATION Install the washers, lower holders and nuts i removed. Placo the handlabars on the lower holders by aligning the punch merks on the hendlebers with the upper surface of the lower holder. Install the upper holders with the punch marks facing forward Tighten the forward bolts firsts then the rearward. TORQUE: 24 Nem (2.4 kgm, 17 fb} Tighten the lower holder nuts 10 the specified torque. TORQUE: 24 Nem (2.4 kg-m, 17 ft-lb) instal tne stertniengine stop switch by elgniag he pin with (1) STASTERIENGINE the hole n the handlebars stor switcy Tighten the forward screw first. than tighten the rearward. % (asin MERRIS) HOLE, (2) SCREWSFRONT WHELL/SUSPENSION/STEERING the grips were removed, apply Honda Bond A or Honde Grip Cement (U.S.A. oniy} to the inside surfaces of the arins and to the clean surface of the left handlebar and throttia arin pipe, Wait 3-6 minutoo and install the grips. Rotate the grips fo: even application of the adhesive. NOTE ‘Allow the adhesive to dry for an four detore using, Apply grease to the throtle giip siding surface and cable guide. Apply grease to the throttle cable ends, and connect the throt- tle cable encs to the throttle crip Apply giezse to the throttle cable slider, and install the slider a8 shown, Assemble the throttle housing halves, and align the mating surface of the halves with the punch mark an the hendlebers, Tighten the upper screw first, then the lower one. Install the master cylinder and position the master cylinder holder with “up'" mark facing up, end loosely instell the holder bolts Align the edge of the maste- cylinder with the punch merk on the nenglebers and tighten the upper bolt fist, then the lower bolt. Connect the frant stop switch wires to the ewicch terminals, Install the left hanclebors switch by aligning the pin with the hole in the handisbars, and tighten the forward screw first, ‘then the rearward screw. 12-4 SN (1) MASTER CYLINDER (1) HOLE SA. 2IN (2) PUNCH MARK (2) LEFT HANDLEBARS SWITCH (3) SCREWSFRONT WHEEL/SUSPENSION/STEERING Install the chatch/choke lever holders and loosely install the |1| HOLDERS holder bolts 21 MATING SURFACE AND PUNCH MARK ‘Agn the mating surface of ihe clutch/choks laver holder with ‘the punch mark on the handlebars and tighten the forward screw first, then tighten the rearward screw. Connect the clutch ewitch wires to the awitch torminale, Route the switch wires and secure them with the wire bands (page 1-12) Adjuat the following: (3) CLUTCH SWITCH — throttle gtip free play (page 3-4) GL SCREWS. WIRES clutch over fee play (oag6 3-12) Ti) SPEEDOMETER FRONT WHEEL CABLE REMOVAL, Raize ths front wheel off the ground by placing @ box or work stand under the engine. Disconnect the speedometer cable from the speedometer gearbox a: the front wheel. Loosen the axla holder nuts and then wemave the frant axle Femove the front wheel INSPECTION FRONT AXLE ‘Sot the axle in V blocks and measure the runout. ‘The actual runout is 1/2 of tha total reading, SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL BEARINGS. Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quiaty. ‘Alco chock thet the boaring outor race fits tightly in tho hub. Remove end discerd the bestings if the races do not tur smoothly, quietly, or if they fit loosely in the hub, NOTE + Replace wheel bearings in pairs. For bearings replacement, see page 12-7.FRONT WHELL/SUSPENSION/STEERING WHEEL RIM RUNOUT Check the rim runout by placing the wheel on a truina stand. ‘Thon epin the wheal by hand, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL: 2.0 mm (0.08 int AXIAL: 2.0 mm (0.08 in} WHEEL BALANCING CAUTION + Wheel balance directly affects the stability, handling ond over alt safety of the motorcycle, Always check balance when tie tire are removed from the rim. ‘optimum balance, the tire balance mark {e paint det on the sldewell) must be located next to the valve stem. Mount the front wheel in a ingpection stand. Spin te wheel, allow It 10 stop, and merk the lowest [heaviest part of the wheal with chalk. Do this two or three times to verify the heaviest area If the wheel ig bslanced, it will not stop consistently in the same position. To balance the wheel, instell wheel weights on the highest side of the rim, the sice opposite te the chalk marks. Add just, enough weight so the whes! does not stop in the same positian when it ie spun. De not add more than 60 grame 12-6