Page 179 of 457
4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
brake fluid level
Below the minimum level mark
a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
ProCarManuals.com
Page 188 of 457
4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
5. Check:
brake fluid level
Below the minimum level mark
a Add the
recommended brake fluid to the proper level.
Refer to ”CHECKING THE BRAKE FLUID
LEVEL“ in chapter 3.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to ”BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
ProCarManuals.com
Page 190 of 457
4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
brake fluid level
Below the minimum level mark
a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
ProCarManuals.com
Page 196 of 457
4-49
FRONT FORKCHAS
NOTE:
WARNING
4. Remove:
damper rod assembly bolt
damper rod assembly
While holding the damper rod assembly with the
damper rod holder
1, loosen the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
inner tube
1
outer tube 2
Bends / damage / scratches Replace.
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
spring free length
a
Out of specification Replace.
Spring free length
236.5 mm (9.31 in)
: 231.8 mm (9.13 in)
3. Check:
damper rod
1
Damage / wear Replace.
Obstruction Blow out all of the oil pas-
sages with compressed air.
damper rod adjusting rod
Bends / damage Replace.
ProCarManuals.com
Page 197 of 457
4-50
FRONT FORKCHAS
CAUTION:
WARNING
NOTE: The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
cap bolt O-ring
1
Damage / wear Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
Make sure the oil levels in both front fork
legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
When assembling the front fork leg, be sure to
replace the following parts:
– outer tube bushing
– oil seal
– dust seal
– Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
inner tube
1
damper rod assembly 2
damper rod assembly bolt
copper washer
New
ProCarManuals.com
Page 207 of 457
4-60
HANDLEBARSCHAS
NOTE:
WARNING
6. Install:
left handlebar switch
1
Align the projection a on the left handlebar
switch with the hole
b in the left handlebar.
7. Install:
handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
8. Adjust:
clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10 15 mm (0.39 0.59 in)
9. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
3 5 mm (0.12 0.20 in)
CHECKING THE STEERING DAMPER
1. Check:
steering damper body
Damage / oil leaks Replace.
(It replace with the assembly.)
steering damper rod
Bends / scratch Replace.
(It replace with the assembly.)
bearing
Damage /pitting Replace.
(It replace with the assembly.)
ProCarManuals.com
Page 215 of 457
4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 mkg, 32 ftlb)
44 Nm (4.4 mkg, 32 ftlb)
44 Nm (4.4 mkg, 32 ftlb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
rear shock absorber rod
Bends / damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks / oil leaks Replace the rear
shock absorber assembly.
spring
Damage / wear Replace the rear shock ab-
sorber assembly.
bushings
Damage / wear Replace.
dust seals
Damage / wear Replace.
bolts
Bends / damage / wear Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
spacers
bearings
Recommended lubricant
Lithium – soap-based grease
2. Install:
rear shock absorber assembly
When installing the rear shock absorber as-
sembly, lift up the swingarm.
Install the connecting arm front bolt from the
right.
3. Tighten:
rear shock absorber assembly upper nut
rear shock absorber assembly lower nut
relay arm-to swingarm nut
4. Install :
EXUP servo motor
Refer to “EXHAUST PIPE” in chapter 5.
bottom cowling
Refer to “COWLINGS” in chapter 3.
ProCarManuals.com
Page 220 of 457
4-73
SWINGARM AND DRIVE CHAINCHAS
NOTE: 3. Wash:
pivot shaft
dust covers
spacer
washers
bearings
Recommended cleaning solvent
Kerosene
4. Check:
dust covers
1
spacer 2
Damage / wear Replace.
bearings
3
Damage / pitting Replace.
5. Check:
connecting arms
1
relay arm 2
Damage / wear Replace.
6. Check:
bearings
3
oil seals 4
Damage / pitting Replace.
7. Check:
collars
5
Damage / scratches Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:
ten-link section
a of the drive chain
Out of specification Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm (5.91 in)
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
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