15.11B ... Then unscrew the sprocket nuts
15.12 Inspect the rubber damper ring
following the procedures described in Chapter 1.
Rear sprocket
Remove the rear wheel (see Chapter 7). Slacken the sprocket nuts before pulling the sprocket coupling out of the hub.
Lift the sprocket coupling out of the hub, unscrew the nuts securing the sprocket to the coupling and remove the sprocket, noting which way round it fits (see illustrations).
If necessary, remove the rubber damper ring from the flange riveted to the outer face of the sprocket and renew it if it is worn or damaged (see illustration).
Install the sprocket onto the coupling with the stamped tooth number marking and riveted flange facing out. Apply some engine oil to the threads of the nuts and tighten them hand-tight.
Press the coupling into the hub and tighten the nuts to the torque setting specified at the beginning of this Chapter.
Install the rear wheel (see Chapter 7), then adjust and lubricate the chain following the procedures described in Chapter 1.
16 Sprocket coupling/rubber
damper - check and renewal ^
Remove the rear wheel (see Chapter 7).
Lift the sprocket coupling out of the hub (see illustration 15.11a). The coupling should be a press fit between the rubber dampers with no freeplay. Check the coupling for cracks and damage, and renew it if necessary.
16.3 Inspect the coupling dampers for wear and deterioration
Remove the rubber dampers from the hub and check them for cracks, hardening and general deterioration and renew them if necessary (see illustration).
Check the condition of the coupling O-ring and renew it if it is damaged or deteriorated. Smear the O-ring with grease before installing the sprocket coupling onto the hub.
Checking and renewal procedures for the coupling bearing are in Chapter 7.
Installation is the reverse of the removal procedure.
16.4 Check the condition of the coupling o-ring
7-1
Chapter 7
Brakes, wheels and tyres
Contents
Brake fluid level check see Daily (pre-ride) checks
Brake light switches - check and replacement see Chapter 9
Brake pad wear check see Chapter 1
Brake hoses and unions - inspection and renewal 10
Brake system - bleeding and fluid change 11
Brake system check see Chapter 1
Front brake caliper - removal, overhaul and installation 3
Front brake disc - inspection, removal and installation 4
Front brake master cylinder - removal, overhaul and installation ... 5
Front brake pads - renewal 2
Front wheel - removal and installation 15
General information 1
Rear drum brake - removal, Inspection and installation 12
Degrees of difficulty
Rear brake caliper - removal, overhaul and installation 7
Rear brake disc - inspection, removal and installation 8
Rear brake master cylinder - removal, overhaul
and installation 9
Rear brake pads - renewal 6
Rear wheel - removal and installation 16
Tyres - general information and fitting 18
Tyres - pressure, tread depth and
condition see Daily (pre-ride) checks
Wheels - general check see Chapter 1
Wheels - alignment check 14
Wheels - inspection and repair 13
Wheel bearings - check see Chapter 1
Wheel bearings - renewal 17
Easy, suitable for novice with little experience
I I
Fairly easy, suitable |k for beginner with ^
some expenence
Fairly difficult,
suitable for competent vj^ DIY mechanic ^S
Difficult, suitable for ^, experienced DIY ^ mechanic JS
Is
suitable for expert DIY >jC or professional ^
Specifications
Note: Where applicable, models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details.
Front brake - all models
Brake fluid type DOT 4
Caliper bore inside diameter R and T models
Standard 27.000 to 27.050 mm
Service limit (max) 27.060 mm
V, W, SW, X, SX, Y and SY models
Standard 30.000 and 32.000 mm
Service limit (max) 30.040 and 32.040 mm
Caliper piston outside diameter R and T models
Standard 26.935 to 26.968 mm
Service limit (min) 26.910 mm
V. W, SW, X, SX, Y and SY models
Standard 29.970 and 31.970 mm
Service limit (min) 4. 29.910 and 31.910 mm
Master cylinder bore inside diameter R and T models
Standard 11.000 to 11.043 mm
Service limit (max) 11.055 mm
V. W, SW, X. SX, Y and SY models
Standard 13.000 mm
Service limit (max) not available
Master cylinder piston outside diameter R and T models
Standard 10.957 to 10.984 mm
Service limit (min) 10.945 mm
V, W, SW, X, SX, Y and SY models
Standard 12.985 mm
Service limit (min) not available
7»2 Brakes, wheels and tyres
Front brake - all models (continued)
Disc thickness - all models
Standard 4.80 to 5.20 mm
Service limit (min) 4.00 mm
Disc maximum runout 0.10 mm
Rear brake - R and T models
Drum inside diameter
Standard 160.00 mm
Service limit (max) 161.00 mm
Shoe lining thickness
Standard 5.00 mm
Service limit (min) 2.10 mm
Rear brake - V, W, SW, X, SX, Y and SY models
Brake fluid type DOT 4
Caliper bore inside diameter
Standard 34.000 mm
Service limit (max) 34.040 mm
Caliper piston outside diameter
Standard 33.970 mm
Service limit (min) 33.910 mm
Master cylinder bore inside diameter
Standard 12.000 mm
Service limit (max) 12.043 mm
Master cylinder piston outside diameter
Standard 11.985 mm
Service limit (min) 11.955 mm
Disc thickness
Standard 5.0 mm
Service limit (min) 4.0 mm
Disc maximum runout 0.10 mm
Wheels
Maximum wheel runout (front and rear)
Axial (side-to-side) 0.3 mm
Radial (out-of-round) 0.3 mm
Maximum axle runout (front and rear) 0.2 mm
Tyres
Tyre pressures see Daily (pre-ride) checks
Tyre sizes
Front 110/80-17 57H
Rear 130/80-17 65H
Torque settings
Front brake - R and T models
Caliper mounting bolts 32 Nm
Caliper pad retaining pin plug 2.5 Nm
Caliper pad retaining pin 18 Nm
Caliper slider pin (in caliper) 23 Nm
Caliper slider pin (in caliper bracket) 13 Nm
Caliper bleed valve 5.5 Nm
Master cylinder clamp bolts 12 Nm
Brake hose banjo bolts 35 Nm
Disc bolts 43 Nm
Front brake - V, W, SW, X, SX, Y and SY models
Caliper mounting bolts 32 Nm
Master cylinder clamp bolts 12 Nm
Brake hose banjo bolts 35 Nm
Rear brake - V, W, SW, X, SX, Y and SY models
Master cylinder mounting bolts 12 Nm
Brake hose banjo bolts 35 Nm
Disc bolts 43 Nm
Front axle bolt 60 Nm
Front axle clamp bolt 27 Nm
Rear axle nut 90 Nm
Rider's footrest bracket bolts 45 Nm
Silencer mounting bolt 27 Nm
Brakes, wheels and tyres 7*3