Chassis

Final gear Disassembly and Reassembly

Final gear disassembly

1.      Remove the nuts and bolts holding the bearing housing.

2.      Remove the ring gear assembly and thrust washer from the final gear case.

3. Remove the self-locking nut from drive pinion by using the holding tool (special tool) and remove the coupling.

Final gear Removal and adjustment

Final gear removal

1.      Remove the rear axle and left shock absorber. Remove the rear wheel (see "REAR WHEEL" section in this chapter).

2.      Remove the 4 nuts holding the final drive unit to the swing arm.

3.      Remove the final gear assembly.

Drive Shaft / Joint

Removal

1.      Remove the rear wheel.

2.      Remove the final gear case assembly.

3.      Remove the drive shaft.

Tires

To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure

Always check and adjust the tire pressures before operating the motorcycle.

Special Tools and Troubleshooting

The following special tools are not available but can be constructed for the final gear disassembly and assembly:

PRESS TOOL NO. 1

PRESS TOOL NO. 2

GEAR CASE HOLDING TOOL

Anti-Dive system

System inspection

1.      Apply the front brake for a few minutes and check to see if any brake fluid leaks out of the pipe joints, the master cylinder, or the actuating piston housing.

2.      Check the fork for fork oil leakage.

3.      Turn the anti-dive adjusting bolt to the maximum position.

Chassis Specifications

1

Steering System
Steering Bearing Type
Bearing Type

Lock-to-iock Angle


Upper Lower

Taper roller bearing

KOYO 32005
KOYO 32006
40°

Rear Suspension (Swingarm and Shocks)

Inspection

1. Remove the rear wheel and both shock absorbers. Grasp the swing arm and try to move it from side to side as shown. There should be no noticeable side play.

Front Wheel

FRONT WHEEL

Removal

1.      Place the motorcycle on the center stand.

2.      Remove the speedometer cable from the speedometer.

3.      Remove the front fender securing bolts and remove the fender.

Front Forks

Removal and disassembly

WARNING: Securely support the motorcycle so it won't fall over when the front wheel and front forks are removed.

1.      Remove the front wheel. Refer to "FRONT WHEEL"