REAR WHEEL/BRAKE/SUSPENSION 75 Nem (7.5 kgan, 54 feb) 45 Nem (4.5 kam, Feb) 95 Nem (8.5 kg-m, 69 tab) 45 Nem 14/6 kom, 32 fel) 45 Nem (4.5 kom, 32 flbp 13-013, REAR WHEEL/BRAKE/SUSPENSION SERVICEINFORMATION 13-1 SHOCK ABSORBER 13-12 TROUBLESHOOTING 13-2 SHOCK LINKAGE 13-15 REAR WHEEL 13-3. SWING ARM 13-18 REAR BRAKE 13-9 SERVICE INFORMATION GENERAL © A box or work stand is required to support the motorcycle. 4 Use genuine suspension linkage and shock absorber pivotimount bolts. Note installation cirection of the bolts, The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Refore disposal of the shock absorber, release the nitrogen (ee page 13-14). + Inhated asbestos fibers have been found to cause resplraiory disease and cancer. Never use an cir hose ar dry brush to clean brake assemblies. + Inthe United States, use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers SPECIFICATION Te STANDARD SERVICE UMAT Rear wheel runout Radial 2 mm (0.08 in) ___ Axl 2.0 mm (0.08 It) Rear brake drum LD. 130.0 mm 6.12 | 181.0 mm (5.16 in) Fear bre shoe wioknese 40mm0.18 i) 2.0 nm 0.08 I Shock aboother spring foe nah 297.8 mm (8.96 in) 796.1 ym (8.28 in [ear susoonsion damper conoresson 39 ka (72.8 28 ka (61.7 b) TORQUE VALUES, Driven eprockat nut 46 Nem [4.6 kg-m, 33 ft-lb) Apply ol ro the threads Rear axle nut 95 Nemn (9.5 kur, 58 fib) Brake erm nut 10 Nem 11.0 kgm, 7 fb) Shock absorber spring lock nut 90 Nem {8.0 kg-m, BS Fb) Shock absorber upper maunt nut 75 Nem 17.5 ka-m, 54 fib) Shock absorbor lower mount bolt 48 Nem 5 kgm, 32 fb) Shock arm-to-shock link nut 45 Nem 14.5 korm, 32 fb) ‘Shock link-o-swing arm nut 45 Nem 14.5 kg-m, 32 frib) Shack arm-to-frame nut 45 Nam (4.5 kg-m, 32 fb} Swing arm pivot nut 110 Nem {11.0 ka-m, 80 ft-b) TOOLS Special Driver shatt (07946—MJ00100. Neodlo bearing romever (07637 MA7co001 NOt avaliadle in U.S.A. Bearing remover, 20 mm 078303710000 Remover handle 07936-3710100 Remover sliding weight 079363710200 13-1REAR WHEEL/BRAKE/SUSPENSION Common Boaring remover head, 17 mm Bearing remiover shaft Driver Attachment, 37 x 40 mm Pilot, 17 mm Attachment, 42 x 47 mm Attachment, 24 x 26 mm Pit, 20 mm Pilot, 22 mm TROUBLESHOOTING Wobble or vibration in motorcycle + Bent rim + Loose wheel bearingts) Loose or bent spokes. Damaged tire Axle net tightened properly Swing arm pivot bearing worn Chain adjusters not acjusted equally Soft suspension Weak spring + Improper shock absorber spring preoad Hard suspension + Improper shock absorber spring preload Bent damper rod + Swing arm pivot bearings damaged + Bent frame or siving arm ‘Suspension ncise + Faulty damper + Loose fasteners + Worn suspension linkage pivot bearingist Poor brake performance + Improper brake adjustment + Worn brake shoes + Brake linings oily, greasy or dirty + Worn brake cam + Worn brake drum + Brake erm serrations improperly engaged + Brake shoes worn at car contact erea 13-2 077460050500 07746—0050100— 077490010000 07746 9010200 077460040400 07746—0010300 077460010700 07746—0040500 07746 9041000 - or equivalent commercially availabe In U.S.A.REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Raise the rear wheel off the ground by placing a box or work stand under the engine. Ramove the adjustar from the brake rod. Disconnect the brake rod from the brake arm. Remove the axle nut and loosen the drive chain adjuster lock rut and adjusting nut. Move the rear wheel forward all the way and detach the drive chain from the ¢riven sprocket Remove the rear axle and rear wheel. Remove the rear brake panal from the rear wheel INSPECTION S91 the axle on V blocks and measure the runout, ‘The actual runout is 1/2 of the total indiceter reading. ‘SERVICE LIMIT: 0.2 mm (0.01 int Turn the inner race of each bearing with your finger. ‘The bearings should turn sincothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearines if the races do not tuin ‘smoothly. quietly, ar if they fit loosely in the hub. NoTE + Replace wheel bearinge in p For baaring roplacoment, see page 13-6. (1) WHEEL BEARING 13-3REAR WHEEL/BRAKE/SUSPENSION Check the rim junout by placing the whee! on a truing stand. Turn the wheel by hand and measure the runout using ¢ dali dicator. SERVICE LIBITS: RADIAL: 2.0 mm (0.08 in} AXIAL: 2.0 mm {0.08 in} is -— Check the condition of the final driven sprocket teath.. | Roplace a worn or damaged sprocket. (1) Good (2) REPLACE NOTE + The crive chain and drive eprokot must sleo be inspoctod if ‘the driven aprokot is worn er damagec.. Never install @ new drive chain on worn sprockets or a worn chain on neve sprockets. Both chain and sprocket must be in good condi tion or the new replacement chain or sprockets will waar a rapidly WHEEL BALANCING Fifer to page 12-6. Do not dd the whee! weight more than 60 grams. (1) WHEEL WEIGHT DISASSEMBLY Pe COLLAR ES Remove the axle collar and dust seal P ‘ Romove the final driven flange. NOTE + When removing the driven sprocket, loosen the sprocket bolt with the driven flange installed 13-4REAR WHEEL/BRAKE/SUSPENSION I the criven flange fits tightly in the hub, drive i out by tapping several locations. UP cOLLaR ‘When replacing the driven ‘lange bearing, remove the collar from the bearing, Drive out the driven flange bearing, if necessary. Romove the driven epreckot from tho driven flango, if nocos- sary. Remove the damper rubbers. Replace the damper rubbers if they are damaged or deteriorat- ed. Remave the O-ring,REAR WHEEL/BRAKE/SUSPENSION Drive out the wheel bearings and the distance coll (1) REMOVER HEAD NOTE + IW the bearings are removed, they shoukd be replaced with TooLs: Bearing remover head, 17 mm 077480060500 or equivalent commercially available in U.S.A. Booring remover shaft 07746—0050100 cr equivalent commercially available in U.S.A. ASSEMBLY (2) DAMPER. (4) DRIVEN. RUBBER FLANGE i () DUST (6) DRIVEN SEAL SPROCKET o “ shee COLLAR (7) SIDE COLLAR monn O-RING 13-6REAR WHEEL/BRAKE/SUSPENSION Place the rim and tire on the work bench. Adjust the pesition so that the distance from the right end sur face of the hub to the side of rim is @ mm {0.9 in} as shown, Tighten the spokes in 2 or 3 progressive steps. TORQUE: 4 Nem 10.4 kg-m, 3 fb) TooL: ‘Spoke wrench C, 5.8.x 6.1mm 07701—0020300 oF equivalent commercially able in U.S.A. Install the rim band, rim lock, cube and the tre with its direc: tional arrow mark pointing in the direction of normal rotation for forward mation, Tighten tha tim lock TORQUE: 13 Nem (1.3 kgm, 9.4 ft-lb) Check the wheel rim runout as shown on page 13-4, end adjust as required Pack the bearing cevities with grease, Drive in the right bearing with te sealed side of the bearing facing out away fram the center of the hub. Be careful not to tilt the bearing while driving it into the hub ‘and make gure that it i fully coated Install the distence collar in the hub, then dive io the left bear Ing with its sealed side facing out, em + Grease on the brake drum reduces stopping power. Keep grease Off the brake dru, TooL Driv 077490010000 Attachment, 37 x 40 mm 077460010200 Pilot, 17 mm 077460040400 Pack a new driven flange bearing with graase, then drive i into the driven flange with kes sealed end facing out. Toots: Driver 07748 -0010000 Attachment, 4247 mm (077460010300 Pilot, 20 mm 077460040500 Install the collar onto the driven flange bearing, If the driven sprocket wee removed, install it with the teath umber facing out. Apply ol to the threads af the driven sprocket bolts and tight fen the sprocket nuts to the specified torque. TORQUE: 46 Nem (4.8 kg-m, 33 ftlb) [8 mm 0-3ini t (2) ATTACHMENTREAR WHEEL/BRAKE/SUSPENSION Install the demper tubbers. (0) DAMPER (2) DRIVEN FLANGE Apply grease to a new O-ring and install it onto the groove of RUBBER eye the wheel hub, P Inatall the driven flange. ‘Apply grease to the cust seal ip and install it. Install the axle collar INSTALLATION Install the brake pnel on the wheel hub. Prace the tear wheel between the swing arm and ral the ariva chain over the drivan sprocket. Lift the rear wheel and insert the tang on the swing arm into ‘the slot in the oraks panel, then insert the reer axle from right side through swing arr, Loosely install the axle nut. Adjust the drive chain (pege 9-6). Tighten the rear axle nut, TORQUE: 90 Nem (9.0 kam, 65 ft1h) 13-8REAR WHEEL/BRAKE/SUSPENSION Connect the brake rod to the breke arm and install the adjust ing nut Adjust the rear brake pedal free play (page 2-11) REAR BRAKE INSPECTION Remove the rear wheel (page 13-2). Ramove the rear brake panel Measure tho roar brake drum 1.0. SERVICE LIMIT: 131 mm (5.16 in} Maacure the rear brake lining shiokne SERVICE LIMIT: 2.0 mm (0.08 in} Replace the brake shoes if thinner than the service limit. DISASSEMBLY Remove the brake shoes and springs from the brake panel. NOTE + Mark the shoas to indicata thai original positions before moving thom,REAR WHEEL/BRAKE/SUSPENSION Remove the following parts from the brake panel: = Bott nut, and brake arm — Indicator plate Brake cam. = Thrust plate — Dust seals Clean all parts throughly. (5) BRAKE, ASSEMBLY (2) DUST SEALS 3) THRUST (4) BRAKE CAM. {1) INDICATOR PLATE (5) BRAKE ‘SHOES (7) BRAKE PANEL (8) BRAKE ARM. Apply greaso to tho dust seals, and install therm inte the brake pane. Install the thrust plate by aligning the pin on the brake panel with tha slot in the plate. 13-10REAR WHEEL/BRAKE/SUSPENSION Apply grease to the brake cam and installit Apply areese to the anchor pin and thrust plate =a + Grease on the brake linings will rechuce stepping power. Keep grease off the brake linings, Wipe excess grease off the came and chor pin. Install the indicator plate onto the brake cam, aligning its tab with cutout on the brake cam. Install the brake arm by aligning the punch marks. Install the belt and tighten the nut te the specified toraue. TORQUE: 10.N-m (1.0 kgm, 7 ft-1b} Position the brake shoes in their original positions snd install (4) graKe the springs. SHOE: Check the rear brake assembly for smooth operation by moving the breke arm EA (2) SPRINGS. torres 1 fT GRake Licht s SWITCH SPRING BRAKE PEDAL REMOVAL/INSTALLATION Remove the following parts: — Brake adjustor — Brake red from the brake arm Brake rod spring — Brake pedal return spring — Brake light switch spring — Beta pin, nut and wash Brake pedal 14) BETA PIN NUT (3) ROD (5) RETURN SPRING AND WASHER SPRING 13-11REAR WHEEL/BRAKE/SUSPENSION eo" Si abvusren (4) spAING (1) BRAKE PEDAL sen (6) Nur o “Apply graase to the dust seal ips and brake pedal pivot, and in stall the breke pecal Install she fallowing parts: — Washer, nut and beta pin — Brake licht switch spring — Brake pedal return spring Brake rod spring — Brake rod to the brake arm — Brake adjuster Acjust the braka padal free play (page 3-11) SHOCK ABSORBER REMOVAL Rise the rear wheel off the ground by placing a box or work stand under the engine, Remove the shock arm bolt (shock link side] and shack absorb: ‘or lowar mount bolt. Flemove the right side cover (page 15:2) and shock absorber Upper mount bolt 5) BETA PIN TH BRAKE LIGHT ITCH SPRING [ : Z. adiwaster, NuT (31 ROD (RETURN SPRING" RipceTa pin SPRING in) LOWER MOUNT (2) UPPER MOUNT 13) SHOCK ARM 3OLT (SHOCK LINK SIDE) 13-12REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY (1) LOCK NUT, Hold the check upper mount Towel Remove the lock nut and adjusting nut. Remove the shock spring. 18 viee with soft jawe ar a chos Sis (2) ADJUSTING NUT, 4 Check the spring fer damage, and meseure the spring ‘ree length. ‘SERVICE Lim ‘+ The damper unitis filed with nitrogen gas under high pressure, do not try to disascennble, +: 235.1 mm (9.26 in) camper rod for trusness. BUSHING (2) DAMPER FUBGER ‘Check the camper unit for oll leaks oF other damage and the {" UPPER MOUNT Check the spring seat stopper, spring seat, spring guide and camper rubber far wear or damage. |S) STOPPER ‘Check the upper mount bushing for wear or demage. 4) DAMPER ROD Mark the 10 mm position as shown of the damper rod. Place the damper rod on a scale and measure the force re- ‘quired to compress the damper 10 mm (0.4 inl. COMPRESSION FORCE: 33 kg (72.8 Ib} If the force required is less than 28 kg |61.7 Ib), gas is leaking. Examine the damper rod and reniace the damper unit if itis bent or ecarad.REAR WHEELIBRAKE/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Contor punch the damper case to mark the dtiling point, ap- | proximazely 16,0 mm (0.63 in} trom the top surface. ‘Wrap the damper unit inside @ plastic bag 1H) PLASTIC BAG Support the demaer unit upright in a vise as shown, (2) DRILL BIT Woy 16.0 mv (0.83 in) Through the open ond of the bag, insert a drill motor with a sharp 2—3 mr (6/64—1/8 in) dil i ow + Domot use a dull dri bit which could causea build-up of exees- ‘sive heat and pressure inside the damper, leading (0 explosion and severe personal injury. + The shoek absorber contains nitrogen gas and oil under high pressure. Da not drill any farther down the damper case than the measurement given above, or you may dill into the off ‘chamber; oi escaping under High pressure may cause serious personal injury. + Always wear eve protection to avoid getting metel shavings in ‘your eyes when the gas pressure is releared. The plastie bag is ‘only intended to shield you from the escaping gas. Hold the bag around the drill moter and briefly run tho dri ‘moot Inside the beg; this will inflate the bag with air from the (3) DAMPER UNIT ‘motor end help keep the bag from getting caught in the bt when you start. ASSEMBLY (2) Lock, (3) SPAING NUT SEAT (1 Agustin (4) DAMPER UNIT NU en sfine (5) SPRING GUIDE 13-14REAR WHEEL/BRAKE/SUSPENSION Install the spring, adjusting nut and lock nut [ Turn the spring acjusting nut until the spring length is as speci- (2) LOCK NUT fied. ‘A: DECREASE THE SPRING LENGTH B: INCREASE THE SPRING LENGTH STANDARD SPRING LENGTH: 237.5 mm (9.35 in) MAXIMUM LENGTI 239.9 mm (9.44 in) MINIMUM LENGTH 235.1 mm (9.26 in) NOTE (One turn of the adjusting nut changes tho epring longth by 1.5 min, Hold the shock absorber upper mount in @ vice with soft jaws. for a shop towel Using pin spanners, tighten the lock aut while holding tho ad justing nut. TORQUE: 90 Nem (9.0 ka-m, 65 fb) Install the breather tube to the scat stepper. Install the shack absorber te the frame with the bresther tube toward the rear Install and tighten the shock absorber upper mount bolt and rut. (a) Lowel mount BOLT iy UPPEn MOUNT BOLT TORQUE: 75 Nem (7.5 kom. 54 ftib) Install and tighten the shock absorber lower mount belt TORQUE: 45 Nem (4.5 kgm, 32 feb) Inctall and tighten the thock arm-to-shock fine holt TORQUE: 45 N-m (4.5 kgm, 32 fib) (3) SHOCK ARIV-TO: Install the right side cover (page 15-2) ‘ pear ~_SHOCK LINK BOLT ‘Cheok the operation of the shack abscrber ipage 3-14) SHOCK LINKAGE REMOVAL TAP SHOCK ARMTTO: FRAME BOLT (2) LoweR MOUNT] Raise the rear whee! of! the ground by placing a work stend or box ungar the angina Femove the following components: — Shook arm-to-shack tink bolt = Shook link-to-swing arm bolt = Shock ink (5) SHOCK ARM-TO- ck abeorber lowor mount bolt SHOCK LINK BOLT — Shock arm-to-frame bolt 8 ee NY BO = Shack arm RMB) stock Lyk Swing ARM BOLT,REAR WHEEL/BRAKE/SUSPENSION (1FCOLLAR (2) NEEDLE BEARINGS (3) DUST. SEALS __-SSHOCK ARM NEEDLE BEARING REPLACEMENT Drive the needle beatings out of the shock arm and ehack link. TooLs: Driver sheft 07946—NJ00100 or Not available in U.S.A Driver 077490070000 Pilot, 22 mm 077450041000 SHOCK ABSORBER LOWER MOUNT BOLT PIVOT AND. SHOCK ARM-TO-SHOCK LINK BOLT PIVOT (1) DRIVER Pack a new needle bearings with multi purpose creas Prose tha neecle bearings into the shock atm until the bearing outer ends are on a level with the shock aim inner edges. NOTE + Press the needle bearing on the stamped ena, Toots: Driver 077490010000 Attachment, 24 x 26 mm 077460010700 (3) NEEDLE BEARINGS 13-16REAR WHEEL/BRAKE/SUSPENSION ‘SHOCK ARM-TO-FRAME BOLT PIVOT (1) NEEDLE BEARING Pack a new needle bearing with multi pursose grace, Measuring with a vernier caliper, press the needle bearing into the shock arm 9 mm (0.35 in) below the outer edge of tne - shock arm. NOTE D + Press the needle bearing on the stamped end. _ — 2mm ToOLs: Driver 07749—0010000 Attachment, 24 x 26 mm 07746-0010700 Rie (2) BEARING (3) INNER Pack a new needle bearings with multi purpose grease Fill the space betwoon noodle bearings with grasee, Press tne needle beerings into the shock link untl the besring outer ends are on a level with the shock link inner edges. NoTE + Press the needle bearing on the stamped end. TooLs: Driver 077490010000 Attachment, 24 x28 mm 077460010700 INSTALLATION Note + Mako sure that the necdle rollers of the needle bearings are in position before installing the pivot collars. Apply multi purpose grease to the shock arm pivot collar sur faces and dust seal lips. Install the collars and dust seals into the shock arm, Apply multi purpose grease 10 the shock tink pivot collar sur- ‘taces anc dust seal lps, Install the coliars and dust seals into the shock link.REAR WHEEL/BRAKE/SUSPENSION Iretall tho shock arm and chock link, and loosely install each bolt ana nut NOTE ‘Tighten each bolt anc nut to the specified torque. ‘TORQUE: Shock link-to-swing arm nut 45 Nem (4.5 kg-m, 32 ft-lb) ‘Shock absorber lower mount bolt 45 Nem (4.5 kg-m, 32 ftb} Shock arm-to-shock link nut: 45 Nom (4.8 keg-m, 32 ft-lb) Shook arm-to-frame nut: 45 N-m (4.5 kg-m, 32 frb) SWING ARM REMOVAL Raise the rear whee! off the ground by placing box or work stand under the engine. Ramove the rear wheel (nage 13-3). Remove the drive chain cover. Remove the shock arm-to-shork link bolt and ehock absorber lowar mount bolt, (1) “UPMARK i) SHOCK ARI-TO- FRAME NUT 5) SHOCK ARN-TO, SHOCK LINK NUT (4) SHOCK LINK “SWING ARM NUT} (1) DRIVE CHAIN COVER |OCK ARM-TO-SHOCK LINK BOLT 13-18REAR WHEEL /BRAKE/SUSPENSION Remove the following parts: — Swing arm nivot cap — Swing arm pivot nut and belt — Swing am > DISASSEMBLY Remove the folowing paris from the swing arm. — Dust seals = Swing atm pivot collar — Diva chain alider — Drive chain guids INSPECTION Inspect the dust seals, pivot collar and needle dearings for wear or damage. Raplaca tham if they have score marks, scratches, or exces ive or abnormal soar. PIVOT BEARING REPLACEMENT Fomove the pivot side collars. Set the needle bearing remover, screw out the pivet bearinas ‘ane digeard thor oo Needle bearing remover (07931 ~MA70000 Bearing remover, 20 mm 07936—3710600 Remover handle 07938—3710100 Remover sliding weight 07938 -3710200 (2) NEEDLE BEARING © 13-19 ———————————————REAR WHEEL/BRAKE/SUSPENSION Pack now nesdle bearings with multi purpose grease. (1) FIVER (2) ATTACHMENT #3) Install the needle besring to the swing arm pivot with the % stamped end facing our, and aress it into che pivot with the pivot side collar Toots: ‘ Driver 07748-00100 (4) NEEDLE aos Attachment, 24 x 26 mm 077460010700 BEARING sss Plot, 20 mm 077460040600 % pont Pross in the othe: needle bearing end side collar. ASSEMBLY (5) CHAIN ADJUSTER. (1) DUST SEAL (2) SIDE COLLAR e (3) NEEDLE @& BEARING a? (8) CHAIN GUIDE (4) COLLAR i CHAIN SLIDER Apply grease to the pivot collar and dust seal lips (2) COLLAR (oust sea. 13-20REAR WHEEL/BRAKE/SUSPENSION Install the collar and dust seals. (1) COLLAR, (3) SWINGARM amy (HUST PIVOT " SEAL Drive chain slider — Drive chain guide Install tho ewing arm to tho frame. From the ight side, insett the siving aim pivot bolt through the ‘swing arm. Instell and tighten the swing arm pivot nut, TORQUE: 110 Nem (11.0 kgm, 80 ft 1b) Install the swing arm pivot cap. Install and tighten the shock absorber lower mount bot. TORQUE: 45 Nem (4.5 ka-m, 32 ftb) Inotall the shock erm-to-sheck link bolt and nut, and tighten ‘the nut. | TORQUE: 45 Nem (4.5 kam, 32 feb) (2) GHEE ARHETO SHOCK LINK B07 13-21 eeeREAR WHEEL/BRAKE/SUSPENSION Install the drive chain cover. (1) DRIVE CHAIN COVER Inseall the rear wheel (page 13-8) 13-22