Maintenance Procedure

A warning

When working with the disc brake, observe the pre­cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong wind is blowing.

6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning of these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE. ^{* ★}

Brake Hoses and Connections Check

• Inspect the brake hose and fittings for deterioration, cracks and signs of leakage.

OThe high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main­tained. Bend and twist the rubber hose while examining it.

★ Replace the hose if any cracks [B] or bulges [C] are no­ticed.

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PERIODIC MAINTENANCE 2-41

Suspension

Front Fork Oil Leak Check

• Visually inspect the front forks [A] for oil leakage, scoring or scratches on the outer surface of the outer tubes.

• Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Check

• Visually inspect the shock absorber [A] for oil leakage.

• If the oil leakage is found on it, replace the shock absorber with a new one.

Swingarm Pivot Lubrication

• The grease nipple [A] is equipped for the lubrication of

Uni-trak Linkage Lubrication In order for the tie-rod and rocker arm to function safely and wear slowly, it should be lubricated in accordance with the Periodic Maintenance Chart.

• For the rocker arm and tie-rod needle bearings, there are

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Maintenance Procedure

Steering

Steering Check

Steering Inspection

• Lift the front wheel off the ground using the jack.

Special Tool - Jack: 57001-1238

• With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.

• If the wheel binds or catches before the stop, the steering is too tight.

• Feel for steering looseness by pushing and pulling the forks.

• If you feel looseness, the steering is too loose.

NOTE

o The cables and wiring will have some effect on the mo- tion of the fork which must be taken into account. o Be sure the wires and cables are properly routed.

O The bearings must be in good condition and properly lubricated in order for any test to be valid.

Steering Adjustment

• Remove:

Upper fairing (see Frame chapter)

Stem Head Nut[A]

Handlebar Position Bolts[B]

• Loosen the upper fork clamp bolts[C].

• Remove the stem head[D], ^•

• Remove the steering stem locknut[A] with the steering stem nut wrench.

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PERIODIC MAINTENANCE 2-43

NOTE

O Turn the stem nut 1/8 turn at a time maximum.

• install the lock washer so that claw of washer fit the notch of steering stem nut.

• First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten steering stem nut ad­ditional more than two notches so that align the notch of stem nut and stem locknut.

• Bend the claw of lock washer to the steering stem locknut notch.

• Install the stem head.

• Tighten:

Torque - Upper Fork Clamp Bolts: 20 N-m (2.0 kgf-m, 14.5 ft-lb)

Handlebar Position Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb)

Steering Stem Head Nut: 78 N-m (8.0 kgf-m, 58 ft-lb)

• Check the steering again.

• If the steering is still too tight or too loose, repeat the ad­justment.

Steering Stem Bearing Lubrication

• Remove the steering stem (see Steering chapter).

• Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.

• Visually check the outer races and the ball bearings.

• Replace the bearing assemblies if they show wear or damage.

• Pack the upper and lower ball bearings [A] in the cages with grease, and apply a light coat of grease to the upper and lower outer races.

• Install the steering stem, and adjust the steering.

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