Special Tool - Top Plug Wrench (45 mm): 57001-1741
Special Tool - Top Plug Wrench (45 mm): 57001-1741
Special Tool - Rod Guide Case Wrench, 35 mm: 57001 -1758
NOTICE
A socket of piston rod guide case is shallow (4 mm) and therefore be sure to check that the wrench (Special Tool: 57001-1758) is securely seated on the piston rod guide case.
When loosening the piston rod guide case. If the wrench is not securely seated on it, the piston rod guide case may brake.
Pump the inner tube up and down at least ten times to expel the oil from the fork.
Pour the fork oil until the upper of the inner tube hole [A].
Fork Oil Recommended Oil: SHOWA SS-19: 44091-0009 Amount (Per Side): When changing oil: Approx. 420 mL (14.2 US oz.) After disassembly and completely dry (Total): 495 ±2.5 mL (16.7 ±0.085 US oz.)
NOTE
Lifting the outer tube, and insert the piston rod assy.
NOTICE
When inserting, be careful not to damage the piston ring [A].
Special Tool - Rod Guide Case Wrench, 35 mm: 57001 -1758
Torque - Piston Rod Guide Case: 90 N·m(9.2 kgf·m, 66 ft·lb)
NOTE
Formula: a × b ÷ (b + c) = d
[a] Specified torque
[b] Length from center of square hole to grip point
[c] Offset = 30 mm
[d] Tightening torque
For an example: 90 N·m × 450 ÷ (450 + 30) = 84 N·m
NOTICE
A socket of piston rod guide case is shallow (4 mm) and therefore be sure to check that the wrench (Special Tool: 57001-1758) is securely seated on the piston rod guide case.
When tightening the piston rod guide case. If the wrench is not securely seated on it, the piston rod guide case may brake.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
Hold the inner tube vertically in a vise.
Wait until the oil level settles.
With the fork fully compressed, insert a tape measure or rod into the piston rod guide case [A], and measure the distance [B] from the top [C] of the outer tube [D] to the oil.
Fork Oil Level (fully compressed) Standard: 85 ±2 mm (3.35 ±0.08 in.)
NOTE
Special Tool - Fork Oil Level Gauge: 57001-1290
Pull the handle slowly to pump out the excess oil until the oil no longer comes out.
If no oil is pumped out, there is insufficient oil in the inner tube. Pour in enough oil, then pump out the excess oil as shown above.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
NOTE
After installing the front fork, adjust the spring preload and damping force correctly.
Oil Pump Installation
Install the outer rotor [A] into the crankcase.
Assemble:
Oil (Water) Pump Shaft [B]
Pin [C]
Inner Rotor [D]
To prevent dropping, apply grease to the pin.
Install the inner rotor assembly into the crankcase.
Fit the slot [E] onto the projection [F].
Replace the O-ring [A ...
Air Cleaner Housing Assembly
Install the ducts to the air cleaner housing.
Fit the projections [A] of the duct into the slits [B] on the
air cleaner housing.
Tighten the screws [A].
Torque - Air Cleaner Housing Duct Screws: 1.1 N·m (0.11
kgf·m, 10 in·lb)
Install:
Air Cleaner Gasket [A]
Duct [B] ...
Drive Chain Slack Inspection
NOTE
Check the slack with the motorcycle setting on its sidestand.
Clean the chain if it is dirty, and lubricate it if it appears
dry.
Check the wheel alignment (see Wheel Alignment Inspection).
Rotate the rear wheel to find the position where the chain
is tightest.
Measure the ver ...