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    4.giảm xóc trước,cổ lái,tay lái

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    4.giảm xóc trước,cổ lái,tay lái

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    Minh Chu
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    6 views23 pages

    4.giảm xóc trước,cổ lái,tay lái

    Uploaded by

    Minh Chu

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    © All Rights Reserved
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    of 23
    6 FORK, TRIPLE CLAMP n © Info TThe hydrautic compression damping determines the fork suspension behavior. = Remove protection caps @. ~ Turn adjusting screws @ clockwise all the way. Info T Adjusting screws @ are located at the bottom end of the fork legs. Make the same adjustment on both fr legs. = Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort TS clicks Standard 15 clicks Sport T2 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. = Mount protection caps @. Info The hydraulic rebound damping determines the fork suspension behavior. = Tumadjusting screns @ clockwise all the way. Info TW pajusting screws @ are located at the top end of the fork legs. Make the same adjustment on both fork legs = Turn counterclockwise by the numberof clicks corresponding to the fork type. Guideline Rebound damping Comfort Te clicks Standard TS clicks Sport TZ clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Preparatory work = Raise the motorcycle with the lft stand. (© p. 9) Main work = Release bleeder screws @. 7 Any excess pressure escapes from the interior of the fork, = Tighten the bleeder screws. 6 FORK, TRIPLE CLAMP 2 Finishing work = Remove the motorcycle from the lft stand. (= p. 9) Preparatory work = Raise the motorcycle wit te lit stand. ( p. 9) Main work = Push dust boots @ of both fork legs downwards. © Info The dust boots remove cust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind the dust boots. If this ditt is not removed, the oil seals behind can start to leak. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. = Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary = Clean and oil the dust boots and inner fork tube of both fork legs. Universal oll spray (7 p. 17) = Press the dust boots back into their normal position. ~ Remove excess oil. Finishing work Remove the motorcycle from the lift stand. (= p. 9) ~ Remove sces @. Takeoff the clamp. = Remove screws @ on te left fork eg. Takeoff the fork protector. ~ Remove screws @ on the right fork leg. Take off the fork protector. = Position the fork protection on the right fork leg. Mount and tighten screws @. Guideline Remaining screws, chassis Ne TONm (7.4 [bff 6 FORK, TRIPLE CLAMP 13 ~ Postion the fork protection onthe let fork lag. Mount an tighten sreus @ Guideline Lo0046.12 o— Me TO Nm (7.4 Tot) Remaining screws, chassis ~ Position the brake line and clamp. Mount and tighten screws @. Preparatory work = Raise the motorcycle with the lift stand. (© p. 9) = Remove the front wheel, (= p. 64) Main work ~ Remove screws @. Take off the clamp. (85 sx 17714) — Remove screws @. = Allow the brake caliper and brake line to hang tension-free to the side. Info Do not kink the brake line. Do not activate the hand brake lever when the brake caliper is removed. (a5 Sx 19716) = Remove serous @ and spacers. = Allon the brake caliper and bree line to hang tension fee to the sie Info Bo not kink the brake line. Do not activate the hand brake lever when the brake caliper is removed. = Loosen screws @. Remove the left fork leg. — Loosen screws @. Remove the right fork leg. Main work = Position the fork legs. Y Bleeder screws @ face forward Info [The second milled groove (rom the top) must be flush with the top edge of the upper triple clamp, 6 FORK, TRIPLE CLAMP 14 ~ Tagen screws @. Guideline Screw, top tiple damp Me 20 Nm (la.8 Ff) = Tighten screws @. Guideline Serew, bottom Wple clamp WE Tenn (La br fD (95 8x 1774) = Position the brake caliper, and mount and tighten screws @. Guideline Screw of brake caliper | WB 25Nm | Locte™ 2437 (18.4 Tot FO ~ Position the brake line and clamp, Mount and tighten screws @, (85 sx 1976) = Postion the brake caliper with spacers and ft and tighten screws @. 00.31 Guideline Screw of brake caliper] MB 25Nm | Loctie® 243% (18.4 tbr FO ~ Postion the brake line and clamp, Mount and tighten sreus @ Finishing work = nstall the front wheel. (2 p. 65) = Remove the motoreyce from the lit stand. (©! p. 9 Condition The fork legs have been removed. (€-0000 = Disassemble the fork legs. (© p. 15) = Disassemble the cartridge. (** p. 17) = Disassemble the compression holder. (= p. 19) = Check the fork legs. (28 p. 20) = Assemble the compression holder. (© p. 21) = Assemble the cartridge. (© p. 22) = Assemble the fork legs. (!" p. 23) WO of. s 201467-01 6 FORK, TRIPLE CLAMP 15 Info I The procedures are the same on both fork legs. Condition The fork legs have been removed. = Remove protection cap @. ~ Make a note of the present state of the rebound @) and compression damping @. = Open the adjusters of the rebound and compression damping completly SS Ao py 201423:10 = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T6125) (™ p. 179) ~ Loosen the screw cover @ Info T_ the screw cover cannot be removed yet. 20142510, = Unclamp the fork leg and clamp it with the axle clamp. i Info Use soft jaws. 201426-10, : = Slide the outer tube dawn, Pull the spring downwards. Mount the special tool on the hexagonal part. Open-end wrench (T14032) (© p. 178) Info T reicad spacers @ should be above the special too 20142710) 6 FORK, TRIPLE CLAMP 16 20142910 20140-10 201431410 20143810, = Clamp the special too! in the vise. Loosen the sorew cover @ ~ Remove screw cap @ with preload spacers = Remove adjusting tube @. = Pull the spring downwards. Remove the special tool. = Remove the spring. = Drain the fork oil Info Dit tte piso oa re way ands back in several ies nr to pump out the cartridge unti itis empty. = Clamp the fork leg with the axle clamp. Guideline Use soft jaws ~ Unscrew and remove compression holder Info I Piace a container underneath to catch any oil tat may run out. = Remove the cartridge 6 FORK, TRIPLE CLAMP 7 Z 20143410 2014910 9 ~ Remove dust toot @. = Remove lock ring Info T The tock ring has a specially finished end against which the screwdriver can be placed. ~ Heat up the outer tube in area @ ofthe lower slicing bushings Guideline 50°C (122 "FI Lt c 20143610, = Pull the outer tube from the inner tube with a jerk Info T The tower stiding bushing @ must be pulled from its bearing seat. = Remove the upper sliding bushing @. info TH without using a toot, pull the stack slightly apart by hand, © 201437.10 20143810. = Take off the lower sliding bushing @. — Take off support ring @. ~ Take of seal ring @. = Takeoff lock ring @. ~ Toke off dust boct @. — Unclamp the fork leg. © Info The steps ae identical for both fork legs Preparatory work = Disassemble the fork legs. (© p. 15) 6 20069410. i FORK, TRIPLE CLAMP 18 oe. Main work = Clamp the special tool in a bench vise. Pin (T605) (= p. 179) Hitch cartridge @ by using the drilled holes. = Unscrew and remove screw sleeve @. Pal piston rod @ out of cartridge @. ‘clamp inthe piston red. Remove water excluder @ Clamping stand (F140165) (> p. 178) + =) 201461-10. a - 20146210 — Remove screw sleeve @ with washer and spring seat from the cartridge. = Degrease the piston rod. = Clamp the piston rod with the special tool. Clamping stand (7140168) ( p. 178) = Remove nut © = Remove shim stack @ completly. 6 FORK, TRIPLE CLAMP 19 Pe = Remove piston @ ~ Remove shim stack @ completely. 20146310, ~ Remove spring @ = Loosen tap rebound @D and remove ~ Remove serine @. = Remove valve @ ofthe rebound damping together withthe spring. = Takeout the piston ro. 20070110 Info The steps are identical for both fork legs. Preparatory work = Disassemble the fork legs. (© p. 15) Main work = Clamp the compression holder in a bench vise using soft jaws. = Remove nut @. = Remove the spring = Remove washer @. = Remove piston © = Remove shim stack @. 6 FORK, TRIPLE CLAMP 20 ~ Remove O-ring @ and seal ring @ from the compression holder. ~ Extract the compression holder. Condition ‘The fork has been disassembled. ‘Check the inner tube and axle clamp for damage. > If there is damage: = Change the inner tube, 200728:10, ‘Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube | 42,975... 43.005 mm (1.69193. 1.69311 in) > Ifthe measured value is less than the specified value: = Change the inner tube, ~ Measure the run-out of the inner tube. Toner tub run-out 5.0.20 mm (= 0.0079 in) » Ifthe measured value is greater than the specified value: = Change the inner tube, ‘Check the outer tube for damage. » If there is damage: = Change the outer tube, 6 FORK, TRIPLE CLAMP 2 = Check the surface ofthe sliding bushing. » Ifthe bronze-colred layer @ under sliding layer @ is visibi: = Replace the sliding bushing. 201466-10, = Check the spring length. Guideline Spring length with preload spacer(s) | 438 mm (17.24 in) » Ifthe measured value is greater than the specified value: = Reduce the thickness of the preload spacers. » Ifthe measured value is less than the specified value: = Increase the thickness of the preload spacers. 20065610. © Info The steps are identical for both fork legs. = Clamp the compression holder in a bench vise using soft jaws. ~ Mount o-ring @ and seal ring @. = Grease the O-ring Lubricant (7158) (©) p. 170) = Mount shim stack @ with the smaller shims facing downward. = Mount piston @ with Oxing @ Info T the side with the larger inside diameter @ faces up. = Grease the piston O-ring. Fork oll (SAE 4) (4860116651) (™ p. 168) ~ Mount washer @. = Mount spring @ withthe tighter col facing downward. = Mount and tighten nut @. Guideline ‘at, compression holder WES Shim (G2 WF) Info T washer @ must be free to move against the spring force. ~ Secure the nut by locking. Extract the compression holder. 6 FORK, TRIPLE CLAMP 2 Info The steps are identical for both fork legs. 200718-10 201464-10. ies | 9% 20146510, Clamp in the piston rod. Clamping stand (1140168) ( p. 178) ‘Mount valve @ of the rebound damping, with the spring and O-ring, Grease the O-ring. Lubricant (T158) (= p. 170) Mount spring @. Grease the O-ring of tap rebound @. Lubricant (T158) (= p. 170) ‘Mount and tighten the tap rebound. Guideline Tap rebound MOx1 8.Nm Loctite® 2701 (23.3 Ibe ft) Postion spring @ Mount shim stack @ with the smaller shims facing downward. Press the shim stack downward against the spring force © Info The shim stack must be pressed downward over the collar Mount piston @ with the piston ring. © Info The side with the largest inside diameter faces downward, ‘Mount shim stack @. © Info Align the triangular plate exactly with the piston opening. ‘Mount and tighten nut @. Guideline Tap rebound nut MGS Nm G7 bw) Info TH Mount the nut with the collar facing downward. Secure the nut by locking Slide screw sleeve @ with the washer and spring seat onto the cartdge. 6 FORK, TRIPLE CLAMP 2 id. Sa 07230 @ = 200099411 Qe a ~ Screw on water excluder @ to the stop. Info T the water excluder must be screwed on tightly against the stop. Do not use a tool = Slide piston rod @ into cartriage @. = Clamp the special tool in a bench vise. Pin (1605) (™ p. 179) = Hitch cartridge @ by using the drilled holes. = Mount and tighten screw sleeve @ Guidatine Screw sleeve M29x1 46 Nm Loctite® 244 (33.9 Ibf ft) © Info The procedures are the same on both fork legs. 0 20143910, Preparatory work = Check the fork legs. (© p. 20) = Assemble the compression holder. (© p. 21) = Assemble the cartridge. (© p. 22) Main work = Clamp the inner tube with the axle clamp. Guideline Use soft jaws. = Mount the special tool. Protecting sleeve (T512) (= p. 179) = Grease and push on dust boot @. Lubricant (TS11) (© p. 170) Info ‘Always replace the dust boot, lock ring, seal ring, and support ring. Mount the sealing lip with the spring expander facing down, = Push on lock ring @ = Grease and push on seal ring @. Lubricant TST) p. 170) Info seating lip downward, open side upward. 6 FORK, TRIPLE CLAMP m4 — Push on support ring @. = Remove the special too. = Sand the edges of the sliding bushings with 600-grit sandpaper; then clean and ‘grease the bushings. Fork oll (SAE 4) (4860116651) (™ p. 168) —_— 200670-10 = Push on lower sliding bushing @. ~ Mount upper sliding bushing @. Info [Without using a tool, pull the stack slightly apart by hand, 1440-10, ~ Heat up outer tube in area @ of the lower sliding bushings. Guidetine 50°C (122 °F = Slide the outer tube onto the inner tube. = Hold the lower sliding bushing with the longer side of the special tool. Mounting tool (T5288) (© p. 179) = Press the sliding bushing all the way into the outer tube, = Position the support ring. ~ Hold the seal ring with the shorter side of the special tool Mounting tool (T5285) (75 p. 179) = Press the seal ring and support ring all the way into the outer tube, J He01s42.0: = Mount lock ring @. Info TH The tock ring must engage audibly 201435-11 = Mount dust boot @. 6 FORK, TRIPLE CLAMP 20144410, 201445-10, 25 Mount adjusting tube @ of the rebound damping inthe carte. =" ‘The adjusting tube extends 5 mm out from the cartridge and can be pressed ‘ inward against the spring force. 2X The adjusting tube protrudes mare than 7 mm (0.275 in) from the cartridge and cannot be pressed in against the resistance af the spring. Screw on fuid barrier @ as fara it wil go, © Into B rosa The tui barrier must be tightened as much as possible. Do not use a to! Install the special tool on the cari. Support too! (140265) (=p. 178) Info T__the special toot must be used to prevent the adjusting tube from being lifted and thus to prevent oi from reaching the piston rod Slide the cartridge into the inner tube. Mount and tighten compression holder @. Guideline Compression holder M2xr 35 Nm (25. otf) Info If the cartridge turns aswell, press the piston rod slighty to the side. Clamp the fork vertically. . Fill twit fork ci Fork ol perfork | 378 mi Fork oil (SAE 4) (4860116681) | ¥ leg (12,78 hoz) _| (= p. 168) Info Tull out the piston rod and push back in a number of times to bleed the car- tridge. Remove pin @ of the special to Suppor tool (7140265) (ip. 178) Pal out the piston rod. Mount the spring, Mount the pin again. Guideline Spring ate Weignt frien <45 ig 299 1B) [32 Ninm (08.3 Wn) Weight of rider: 45... 55 kg (99... | 3.4 Nimm (19.4 Ib/in) 121 Ib) 20144610, Weight of rider: > 55 kg 3.6 Nimm (20.6 Ibn) © 121 1b) Pll the spring downwards. Mount the spacial toal on the hexagonal par. (Open-end wrench (T14032) (= p. 178) Remove the special tool ‘Support tool (7140268) (© p. 178) 6 201448-10, 20144810 FORK, TRIPLE CLAMP 28 = Clamp the special too! in the vise. ~ Lubricate the thread of the piston rod. Tabricant (F155) = p. 170) = Grease the upper eage @ ofthe piston rod ibrcant (7158) p. 170) — Screw the screw cover with the preload spacers onto the piston rod. © Info I The screw cover must be screwed to the stop before the piston rod starts to turn, In case of tight piston rod threads, it must be held to keep it from turning. If the screw cover is not screwed to the stop, the rebound adjust- ment will not work correctly. = Tighten the screw cover. Guidetine ‘Screw cap on piston rod iad 25 Nm (18.4 tof A) = Release the special tool Pull the spring downward and remove the special tool = Push the outer tube upward. = Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T6125) (= p. 179) = Grease the O-ring of the serew cover. Lubricant (7158) (™ p. 170) = Screw on and tighten the screw cover. Guideline ‘Screw cap on oulter tube Ma6x1 50 Nm (36.9 tof FY nerve 1 Tur the adsting screw of ebound damping @ and the adhsing screw ot compression damping @ clockwise as fara possible = Tum counterclocase bythe numberof clicks corresponding to the fork type Guideline Rebound damping Comfort 18 clicks ‘Standard 16 clicks Sport 12 clicks Compression damping Comfort 18 clicks ‘Standard 15 clicks Sport 12 clicks 6 FORK, TRIPLE CLAMP 2 mative 2 Warning Danger of accident Modifications to the suspension setting may seri- ously alter the handling characteristic. Extreme modifications to the suspension setting may cause @ serious deterioration in the handling characteristic and overload components. Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Turn the adjusting serens tothe position they were in Before dismantling. Mount protection cap @ @ So Remove the lower triple clamp. ( Install the lower triple clamp. ( p.27) p. 28) Preparatory work Raise the motorcycle with the lift stand. (© p. 9) Remove the front wheel. (= p. 64) Remove the fork legs. (= p. 13) Remove the start number plate. ( Remove the front fender, (® p. 62) Remove the handlebar cushion, in work Remove fuel tank breather @. Remove nut @. Remove screw @, pull off the upper triple clamp with the han- dlebar, and hang it to the side, Info Cover the components to protect them against damage. Do not bend the cables and lines. p. 62) Remove protective rng @. Take ff the lower triple clamp with the sterng ste. Remove the upper steering head bearing 6 FORK, TRIPLE CLAMP 28 Oo (i 00@ 0250-10) Main work = Clean the bearing and sealing elements, check for damage, and grease, High viscosity grease (© 9. 170) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing, = Slide on O-ring @. ~ Position protective ring @. = Position the upper triple clamp with the handlebar. = Mount nut @, but do not tighten it yet. = Posi nthe fork legs. Y Bleeder screws @ face forward © Info TL The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. = Tighten screws @, Guidetine ‘Screw, batiom tiple clamp ue 15 Nm (LLL bf fo 6 FORK, TRIPLE CLAMP 23 Tighten out © Guidetine Nut, sieving tern M2Ox15 TONm (74 Tor Position the fuel tank breather. Mount and tighten screw @. Guideline Screw, top triple clamp NB 20 Nm (14.8 tof #9 Using plastic hammer, tap ity on the upper rile clamp to avid stresses, Tighten scons @ Guideline ‘Screw, top triple clamp Me 20 Nm (24.8 tof fo (85 SK 17/14) (85 sx 19/16) = Position the brake caliper, and mount and tighten serene @ Guideline Screw of brake caliper | Mi 25 Nm Toctite® 243 (18.4 tbr FO = Position the brake tine and clamp. Mount and inten serens © Position the brae clier with spacers and fit and tighten screws @. Guideline Screw of brake caliper | MB 25 Nm Loctite® 243 (18.4 tof FO ~ Poston the brake ine and clamp, Mount and tighten serews @ Finishing work Install the front fender. (Sp. 62) Install the start number plate. (© p. 62) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Install the front wheel. (2 p. 65) Check the play of the steering head bearing. (% p. 30) Remove the motorcycle from the lift stand. (= p. 9) Position the handlebar cushion and secure with cable ties. 6 FORK, TRIPLE CLAMP 30 Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. = Correct incorract steering head bearing play immediately. Info Hr the bike is ridden with play inthe steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. Preparatory work = Raise the motorcycle with the lft stand. (= p. 9) Main work = Move the handlebar to the straight-ahead position. Move the fork legs to and fra in the direction of travel To play should be noticeable nthe steering head bearing. La ~ Mitre rte pay eset

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