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FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (1) GEAR BOX (2) DUST SEAL Remove the spaedemator gearaox from the right side of wheel hub. Remove the dust seal and soesdometer gear retainer } Remove the side collar, front brake dise, dust seal and the hub (3) DUST | SEAL Remove tho wheol bearings and distance caller. 07746—0050400 or equivalent commarcially available in U.S.A, Bearing remover shat: 07746—0050100 or equivalent commercially available in U.S.A. NOTE + Replace the wheel bearing with a now one, whenever the ), Baeting ie removed + Replace the wheel bearings in pale. (2) BEARING REMOVER HEAD] 12-7FRONT WHELL/SUSPENSION/STEERING ASSEMBLY + Do not get grease on the brake dise or stopping power will be reduced. (1) SPEEDOMETER GEARBOX So sm (2) SPEEDOMETER GEAR 43) pusT seat cay weaning ofl Placa the rim on the work bench. Place the hub with the dise sida down and begin lacing with new spokes. ‘Adjust the hub position so thet the distance from the disc out side surface to the side of rim is 22.25 mm (0.876 ini es shown, Tightan tho spokes in 2 or 3 progroscive steps. TORQUE: 4 Nom (0.4 Kg-m, 3 feb} Tool: SPOKE WRENCH C, 6.8 x 8.1 mm 07701 —0020200 or equivalent commorcially available in U.S.A, Pack new wheel bearings with greese, Drive in tho right bearing firat until it costs completely, Install the distance collar and drive in the left bearing. NOTE install the bearngs with their sealed ends facing outside. + Drive the bearings in perpendiculaiy. 07749-0010000 077460010100 07746—0040300 Attachment, 32 x 35. mm. Pilot, 15 mm Check the whos! uncut (page 12-6). Install the rm lock, rim bang, tube and tire NOTE + Install the tre with its directional arrow gcinting in the di rection of normal rotation for fowaird motion. 12-8 (6) DISTANCE COLLAR (6) BEARING (2) DUST SEAL (@) SIDE COLLAR, (9) HUB BEARING (19) Disc __ | 22.26 mm (0.878 in) (2) ATTACHMENT ‘AND PILOT. iy DpWERFRONT WHEEL/SUSPENSION/STEERING Apply alocking agent to the threads of the hub cover sciews, 11) BRAKE (21 BOLT. (3) SIDE COLLAR, and secure the hub cover with the screws, DISC f Install the brake disc yrith the stemped side facing out, and secure the dise with four bolts TORQUE: 15 Nem (1.5 kgem, 11 feb) ‘Apply grease to the dust seal lips and install It Install the left side collar. (6) HUB ios COVER (5) SCREW ta) DUST SEAL Inatall the shims inta the speedomater gearbox Apply grease to the inside surface of the goarbox and goar ‘teeth, anc install the gear Into the gearbox. (1) SPEEDOMETER, San i GEAR Install the specdoreter gear retainer, aligning tabs of the re tainer with the grooves in the veel hub. Apply grease 10 the dust seal bub. Install the speedometer gearbox onto the dust seal. engaging the tebe of the gear retainer with the bosses of th: ter gear cach other. and install it into the whealFRONT WHELL/SUSPENSION/STEERING INSTALLATION Place the front wheel between the fork legs. Fit the ealizer over the brake disc, teking care not to damage {the brake pads. Clean the axle and helder Inetall tho axle through the speedometer goerbox and wheel ub. Set the speedometer gearbox tab against the behind of the tang on the fork slider UP" MARK If you removed the axle holder, instal it with “UP mark, fecing up. Install the axle holder nuts locsely. ‘Tighten the front axle to the specified torgue. TORQUE: 86 Nem (6.5 kgm, 47 fb) Connect the spe with the screw. jomerer cable te the gearbox, and secure it With the front brake applied, pump the front suspension up and down severe! times to seat the axlo. Tighten the front axla holder nuts, the upper nuts first, then the lower nuts in 2—3 steps, TORQUE: 12 Nem (1.2 kgm, 9 ft-lb) FORK REMOVAL (1) FRONT FENDER (2) FORK Remove the following parts. BRACE: Front wheel (page 12-5) Front fender — Fork brace — Retlectors In) REFLECTORS: = Speedometer cable clam. — Brake hose clamp — Brake caliper Ipags 14-9) NOTE Se S (2) BRAKE q + ris no: necessary to hore. ae (a) SPEEDOMETER caale clamp 12-10FRONT WHEEL/SUSPENSION/STEERING Loosen the upper ‘ork pinch bolts first, then the fork cap bolts. Holding the fork legs, loosen the lower fork pinch bolts, then romove the fork lege. '3| UPPER FORK PINCH BOLTS DISASSEMBLY £1) FORK BOOT Loosen the boot band screws and remove the fork boot and boot bands. Romove the fork cap bol. + The cap bolts are under spring pressure. Use eare when remov- ing and weur eye and jace protection. (1) SPRING (a1 FORK Remove the spacer, spring seat and fork spring. Drain the fork fluid by pumping the ‘ork tube in and out several times. Check the spacer and spring scat for wear or damage.FRONT WHELL/SUSPENSION/STEERING Hold the fork slider in 2 vise with soft jaws or @ shop rowel Remove the fork slider socket bot. CAUTION + Do not distor: the fork slider in a vise Remove the fork piston anc rebound soring. Remove the dust caal and circlip. CAUTION + Be careful not to damage the fork tube, (2rciRCLIP Pull the fork tubo out until it stope. Then move it in and out, ‘tapping the bushing lightly until the fork tube separates from ‘he fork slider. The slider bushing will be forced out by the fork tube bushing. Remove the oil lock piace from the Fork alid Remove the oll seal, back-up ring and slider bushing from the ‘ork tube, PIECE Do net remove the fork tube bushing until inspection determi is nacessary (page 12-13). g BUSHING. (5) SLIDER. BUSHING. (4) O1L SEAL 12-12os -( S- FRONT WHEEL/SUSPENSION/STEERING INSPECTION Measure the fork 5 free length, ‘SERVICE LIMIT: 593.3 mm (23.36 In) Chack the oil lock piece. rebound spring and fork tube piston ring for damage er wear Replace if necessan Chack tha fork slider, fork tube and fork piston for scering scratches, deformation or excessive weer. Replace any camponents which ara worn or camaged. Sot the fork tube on V blocks and measure the runout, ‘The actual runout is 1/2 of the total indicator reading, SERVICE LIMIT: 0.2 mm (0.01 ind (1) OL LOCK PIECE (3) REBOUND SPRING ©: (2) FORK SLIDER (2) PISTON RING 12-13FRONT WHELL/SUSPENSION/STEERING Visually Inspact the slider an fork tube bushings. Replace the bushings if there is excessive scoring or scratch- ing. or ifthe teflon is worn so that the copper surface anpears ‘on more than 3/4 of she entire surface. (1) BUSHING (2) BACK-UP RING Check the back-up ring; replace It if there 1s any distortion at ‘the ocints shown. (3) CHECK POINTS ASSEMBLY (a) SPACER 2) WASHER, (WOUSTSEAL 12) FORK Boor ne cRcur ~e "roma | Lo FORK TUBE (17) OW SEAL, tis) aac aed AING © & a = P (9 Fone SPRING a |onaror7 RING gj ineom—i! ey Sa PISTON Sa 113) FORK TUBE A j BUSHING. Flee u 3 (g) REBOUND 7S 4 serine 0 Jay FORK SUIGER ——_(@) OIL Lack. lece ; (1) OL, LOCK (2) FORK a) StibER Insert the fork giston with the rebound spring and with its ore eB 8 SER piston ring side facing up. Apply ATF to a new oil seal lia, Install the slider busking, back-up ring and new cil seal onto ‘the fork tube. NOTE Install tre oll seal with the Sot the oll tock piece onto the end of the fork piston, then ig) FORK (6) BACKUP. Insert the fork tube Into the fork slider. SLIDER RING (4) OIL SEAL SS 12-14 eee errr er eTETTTE ES TT eTFRONT WHEEL/SUSPENSION/STEERING ‘Temporary install the ‘ork spring, spring seat, spacer, washer (1) SockeT BOLT ‘and fork cap bolt into the fork tube, Place the fork slider in @ vise with soft jaws or a shop towel. ‘Apply a locking agent to tie socket bol: threads and torque the fork slider socket boit. TORQUE: 20 Nem (2.0 kegem, 14 ft-lb} Drive the oll seal inte place using a fork seal driver end ettach- (1) FORK SEAL DRIVER | i ment. ‘oous: Fotk seal driver 07947—KA50100 Fork seal driver attachment —-_-07947—KFO0100 Install the circlip and dust coal (2) DUST SEAL Note + Be careful net to damage the fork tube sliding surface. + Make sure the circiip Is seated securely in the fork sider groove. Remove the fork cap bolt, washer, spzcer, spring seat and fork spring. Pour in the specified emount of ATF. ‘SPECIFIED FLUID: ATF CAPACITY: 592 cc (20.0 US oz, 20.8 Imp 021 Slowly compress the fotk leg up and down about five times, then megsure the ol level from the top of the tube with he ‘ork leg fully compressed. NOTE + Make sure the oil level is the same in both fork tubes, STANDARD OIL LEVEL: 120 mm (4.7 in} 12-15FRONT WHELL/SUSPENSION/STEERING Wipe any ail off the fork spring Install the fork spring into the fork tube with its nallow pitch end facing down, end install the spring seat and spacer. (1) FORK CAP (2) O RING BOLT sins Apply ATF to « new O-ting end instal it onto the Fork cap bolt. Put the wasiter onto the fork cag bolt, and screwr the cap bolt in-the fork tube. (31 WASHER Install the fork boot with the breather holes facing the rear. HT FORK BOOT !2)!.50042) BREATHER HOLES Install the lower band with the screw head facing eur, and : tighten it Loosely install the upper band with the screw head facing out. INSTALLATION Install the fork legs through the steering stem and steering top brioge. Align the tops of the fork tube and steering top bridge and tiahten the lower fork pinch bolts, TORQUE: 33 Nom (3.3 kg-m, 24 feb) Tighton the fork cap belts to the specified zorque. TORQUE: 34 Nem (2.3 kg-mn, 17 feb) Tighten the upper fork pinch bolts to the specified toraue. TORQUE: 28 Nem (2.8 kg-m, 20 ft-lb) 12-16FRONT WHEEL/SUSPENSION/STEERING Install the brake caliyer and calipar bracket onto the lett fork (1) REFLECTORS slider, and secure the bracket with the boits. TORQUE: 25 Nem (2.5 keg-m, 18 feb} Secure the brako hose with the brace hose clamp. Secure the speedometer with the speedometer clamp. Install the reflectors as shown. : (a secéoomerer" CABLE CLAMP ) Pl the fork boots up to the steering bottom bridge, and tight- (1) 8907. ‘an tha boot band screws, Banos ——— Install the fork brace and front fender anto the fork legs and |1) FRONT FENDER. s0oure thom with the four bolts Instell the front wheel (page 12-10) (3) FORK BRACE STEERING STEM REMOVAL Romave the follawing: — handlebars (page 12-31 — ignition switch {page 19-6) — front wheel (page 12-5) stom nut cap — brake hose clampFRONT WHELL/SUSPENSION/STEERING Fomeve the air guide piate and brake pipe attaching bolts. Remove the steering stam nut (1) EXTENSION BAR Toots: Lock nut wrench, 30 x 32 mm 077160020400 (or equivalent commercially availaale in U.S.A, Extonsion bar 077160020500 ‘r equivalent commercially available in U.S.A. Loosen the upper Tork pinch balts and ramove the steering top bridge. Remove the fork lege. Hold the stearing stem to prevent it from felling. Fomove the stecring adjustment nut rooLs: Steering stem socket 07916—KA50100 Extension bar ‘Adjustable pin spanner move the Fellow (0) DUST (2) UPPER WNC YR STH SETI eusteed Seat |” Race Sev — upoer bearing inn = upper bearing steering stem Check the dust sesl, inner race, upper and lower besrings and outer races for wear or damage. Replace if necessary. Remove the lower bearing from the steering stem, (5) UPPER BEARING 12-18FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT NOTE + Always replace the bearing and rece as a set. emove the bearing inner race and dust seal from the steering stem, NOTE + Temporarily install the steering stem nut onto the steering stom te prevent the stom threade from being demagac when removing lower inner race. Install a new dust seal onto the steering stem and press the lower bearing inner race anto the stem with the special soo! Toots: Steeting stem driver 97946—4300101 or Not available in U.S.A. Stosring stem driver 97946—Ma00000 with Steering bearing attachment GN HTS¢ (U.S.A. only) Remove the upner and lower outer races using special tool Toots: W race remover 97953-10000 Not available in U.S.A, — Ball race remover 97953—MJ10100 attachment Not available in U.S.A, = Driver hana 97953—MJ10200 or Not available in U.S.A, Ball race remover 07953—MJ1000A, IUSA. only) Diivo now outer racea inta the etsering head. 97749-0010000 Attachment, 42 x 47 mm 07746—0010300 (1) DUST SEAL (2) INNER RACEFRONT WHELL/SUSPENSION/STEERING INSTALLATION MIT LOWER BEAAING BAM (2) bust x SEAL Pack a new bearing cavities with grease. Inetall the lowor toaring onto the stooring atom, then insert the steering stam through the steering head. Install the upper bearing end beering inner race. Apply grease to the dust se: head and install it onto the stearing 11) STEERING STENT SOCKET Install and tighten the steering adjustment nut to the specified torque. TORQUE: 5 N-m (0.5 kg-m, 3.6 fb) stem socket 07916—KA50100 oF Adjustable pin spannsr 077020020001 Extension bar 07716—0020500 or equivalent commercially available in U.S.A. Turn the stooring stom lock to lock 56 timse to.ceat the bear ings, and check the sieering stem for up-and-down move ment. Tighten the adjustment nut-to the specified torque again. (1) TOP BRIDGE Install the staering top bridge and steering stem nut, ‘Ternporarity install the ‘ork legs. Tighten the steering stem nut to the specified torque: TORQUE: 100 Num (10.0 kg-m, 72 fe-10) Toots: Lock nut wrench, 30 x32 mm —07716—0020400 for equivalent commercially avalable in U.S.A, Extension bar 07716-0020500 or eauivalent commercially avalable in U.S.A, ‘Secure the brake pipe to the steering bottom bridge with twa bolts. Install the air guide plate with twe bola, 12-20FRONT WHEEL/SUSPENSION/STEERING {Install tie following components: Fork legs page 12-16 — Brake hose lamp Stom nis cap. — Ignition switch (page 19-7) Handlebars ‘page 12-3) — Front wheel (page 12-10) [2) STEM NUT_CAP| 12-21