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.
4. Compress the front forks while applying the front brake. If the front forks are compressed easily, the anti-dive system may be damaged.
Removal
1. Release the air from the front fork by pressing the air valve pin.
2. Remove the drain screw from front fork and drain the fork oil.
3. Remove the brake hose from the actuating piston housing.
1. Actuating piston housing
4. Remove the bolts securing the actuating piston housing, and remove the housing from the anti-dive valve housing.
1 Securing bolt 2. Anti-dive valve hausing
5. Remove the anti-dive adjusting bolt cover.
CAUTION: The adjusting bolt can not be removed from its seat.
1. Adjusting bolt
6. Remove the bolts securing the anti-dive valve assembly and remove the housing assembly from the front fork. Remove two O-rings from the front fork.
1. Anti-dive valve assembly 2. 0-ring
Inspection
NOTE: The anti-dive valve housing can not be disassembled so it must be replaced with a new one if the anti-dive valve malfunction is found.
1. Remove the circlip and remove the actuating piston from the actuating piston housing.
CAUTION: Do not remove the O-ring from the actuating piston.
1. Circlip 2. Actuating piston
2. Check the piston, O-ring, and cylinder for wear, cracks, rust, and/or scrathces. If any damage is found, replace the actuating piston housing assembly.
3. Check the piston separator for cracks and replace if damaged.
4. Check the spring seat rivetted portion of the adjusting bolt for damage. Replace the adjusting bolt seat assembly if damgaed.
Assembly
1. Lubricate the actuating piston with clean brake fluid, and carefully insert the piston into the actuating piston housing cylinder until the shoulder of the piston is flush with the cylinder edge.
2. Install the washer and circlip.
3. Install the separator into the actuating piston housing.
4. Install new O-rings around the front fork oil pasages.
5. Install the anti-dive valve housing onto the front fork and secure it with bolts. Torque the bolts to the specification.
Tightening torque: 7 Nm (07 rrvkg, 5.1 ft-lb)
6. Install the actuating piston housing onto the anti-dive valve housing and secure it with two bolts. Torque the bolts to the specification.
Tightening torque: 5 Nm (0.5 mkg, 3.6 ft-lb)
7. Connect the brake hose to the actuating piston housing with the union bolt and copper washers. Torque it to the specification.
Tightening torque: 26 Nm (2.6 mkg, 19 ft-lb)
8. Pour the specified amount of front fork oil into the fork inner tube.
Front fork oil capacity (each leg): 286 ± 4 cm3 (10.1 ± 0.14 imp oz,
9.67 ± 0.14 US oz) Recommended oil: SAE 5W type SE motor oil or equivalent
9. Add proper brake fluid into the brake reservoir being careful not to spill or overflow.
10. Connect the clear plastic tube of 4.5 mm (0.18 in) in inside diameter tightly to the actuating piston housing bleed screw. Put the other end of the tube into a container.
11. Slowly apply the brake lever several times. Pull in the lever. Hold the lever in the "on" position. Loosen the bleed screw. Allow the lever to travel slowly toward its limit. When the limit is reached, tighten the bleed screw. Then release the lever.
12. Repeat the above step until ail air bubbles are removed from the brake line. It may be necessary to bleed the caliper cylinder in the same manner.
NOTE: If the bleeding is difficult it may be necessary to let the brake fluid in the system stabilize for a few hours and repeat the bleeding procedure.
13. Fill the fork with air using a manual air pump or other pressurized air supply.
Standard air pressure: 39.2 kPa (0.4 kg/cm2, 5.7 psi)
14. Adjust the anti-dive adjusting bolt. See Anti-Dive Adjustment
WARNING: The anti-dive setting must be the same on both anti-dive units.
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