12. FRONT WHEEL/SUSPENSION/STEERING

really big verson

Page 12-1

SERVICE INFORMATION

WARNING

• Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use adn air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method abroved OSHA designed to minimize the hazard caused by airborne asbestos fibers.

GENERAL

• A jack or other support is rwquired to suppor the motorcycle durring front end service.
• Front brake service, refer to section 14.
• For headlight, instrument and ignition switch services and inspections, refer to section 18.

SPECIFICATIONS

Page 12-2

TROUBLESHOOTING

• Steering bearing adjustment nut too tight
• Faulty steering stem bearings
• Insufficient air in front tire

• Bent fork legs
• Bent front axle, wheel installed incorrectly
• Unequal oil quantity in each fork tube

• Distorted rim
• Worn front wheel bearings
• Axle or axle holder not tightened properly

• Weak fork springs
• Insufficient fluid in fork legs

• Fork oil level too high
• Fork tube(s) bent or fork slider(s) damaged

• Slider binding
• Insufficient fluid in fork legs
• Loose fork leg fasteners

Page 12-3

HANDLEBARS

REMOVAL

• rear view mirror from the master cylinder
• master cylinder holder mounting bolts and holder
• right handlebar retainer ring and loosen the handlebar pinch bolt.
• the right handlebar from the fork tube.

Disconnect the clutch switch wires from the switch terminals.
Remove the following:

• rear view mirror from cluch lever holder.
• clutch lever holder mounting bolts and holder.
• left handlebar switch screws and switch.

Remove the left handlebar retainer ring and loosen the left handlebar pinch bolt.

Remove the left handlebar from the fork tube.

Page 12-4

HANDLEBAR WEIGHT REPLACEMENT

Remove the handlebar weight by turning the grip end weight.

NOTE

• Apply lubricant spray (CRC 5-56 or equivalent) throught the tab hooking hole to the rubber suspension in order to easy removal.

Remove the grip end weight by removing the mouinting screw from the handlebar weight.
Discard the used retainer

Install the new retainer onto the handlebar weight.
Install the grip end weight onto the handlebar weight aligning the boss with slot.
Clean and apply a locking agent to the mounting screw threads and tighten it securely.

Insert the handlebar weight assembly onto the handlebar.

Hooking the retainer tab to the hooking hole securely.

Install the grip onto the handlebar.

Apply Honda Bond A to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe. Wait 3-5 minutes and install the grips.
Rotate the grips for even application of the adhesive. NOTE

• Allow the adhesive to dry for an hour before using.

Page 12-5

INSTALLATION

TORQUE: 27 N.m (2.7 kg-m, 20 ft-lb, 240 in-lb)

Align the locating pin on the right handlebar switch with the hole in the handlebar.

Apply clean grease to the throttle cables and apply clean oil to the throttle pipe sliding surface and connect the throttle cables to the throttle pipe.

Slide the throttle pipe onto the handlebar.
Install the right grip end-weight and tighten the screw.

Place the front brake master cylinder on the handlebar adn install the master cylinder holder with the "UP" mark facing up.

Align the end of the holder with the punch mark on the handlebar. Tightent the upper holder bolt first, then tighten the lower bolt.

TORQUE: 12 N.m (1.2 kg-m, 9 ft-lb, 108 in-lb)

Connect the front brake switch wire.

Install the right handlebar switch mounting screws.
tighten the front screw first, then tighten the rear screw.
Install the throttle cables to the carburetor and adjust the throttle grip free play (page 3-4).

Install the right rear-view mirror intohe master cylinder holder.

Page 12-6

Install the right rear view mirror in the holder.
Secure the wires with wire bands.

Install the clutch lever and holder with the "UP" mark facing up.
Align the end of the holder with the punch mark on the handlebar and tighten the upper bolts first then tighten the lower bolt.

TORQUE: 12 N.m (1.2 kg-m, 9 ft-lb, 108 in-lb)

Adjust the following:

• throttle operation and free play (page 3-4).
• cluch lever free play (page 3-15).

Page 12-7

FRONT WHEEL

REMOVAL

Disconnect the speedometer cable from the speedometer gear box by removing the cable set screw.
Remove the brake caliper mounting bolts and brake caliper.

CAUTION

• Support the caliper assembly so that it does not hang on the brake hose. Do not twist the brake hose.

NOTE

• If you squeeze the front brake lever after the caliper is removed, the caliper piston will move out and make assembly difficult.

Loosen the right and left front axle pinch bolts, and remove the axle bolt.

Remove the axle and the front wheel.

Remove the side collar from the right side and remove the speedometer gear box from the left side.

Page 12-8

INSPECTION

SERVICE LIMIT: 0.2 mm (0.01 in)

Wheel rim runout
Check the rim runout by placing the wheel in a truing stand.
Spin the wheel slowly and read the runout using a dial indicator.

SERVICE LIMITS:
   RADIAL RUNOUT: 2.0 mm (0.08 in)
   AXIAL RUNOUT: 2.0 mm (0.08 in)

Wheel Balance

CAUTION

• Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Always check balance when the tire has been removed from the rim.

NOTE

• For optimum balance, the tire balance mark la paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary.

Mount the wheel, tire and brake disc assembly in an inspection stand.
Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk.
Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same po sition.

Page 12-9

To balance the wheel, install wheel weights on the highest side of the rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it's spun. Do not add more than 60 grams to the front wheel.

Wheel bearing
Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub.

Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.

NOTE

• Replace hub bearings in pairs.

BEARING REPLACEMENT

Install the bearing remover head into the bearing.
From the opposite side install the bearing remover shaft and drive the bearing out of the wheel.

NOTE

• If the bearings are removed, they must be replaced witb new ones.

TOOLS:
Bearing remover shaft	07746-0050100
Bearing remover head, 20 mm	07746-0050600

Page 12-10

Remove the distance collar from the wheel hub.
Remove the other bearing from the hub using the same tools.

Drive a new right bearing into the wheel until it is fully seated first.

TOOLS:
Driver	07749-0010000
Attachment, 42 x 47 mm	07746-0010300
Pilot, 20 mm	07746-0040500

NOTE

• Do not allow the bearings to tilt while driving them in.
• Never install an old bearing, once a bearing is removed, it must be replaced with a new one.

Install the distance collar into the wheel hub.
Drive a new left bearing into the wheel until it is fully seated.

ASSEMBLY

• The front wheel has no rim band.

WARNING

• Do not get grease on the brake disc or stopping power will be reduced.

Page 12-11

Install the brake disc onto the wheel hub with the minimum thickness marking (MIN TH 4.0 mm) facing out.
Clean and apply locking agent to the mounting bolt threads.
Tighten the bolts to the specified torque in a crisscross pattern in 2 or 3 steps.

TORQUE: 40 N.m (4.0 kg-m, 29 ft-lb)

WARNING

• Do not get grease on the brake disc or stopping power will be reduced.

Coat the speedometer gear retainer with clean grease and install the retainer into the wheel hub, aligning the tangs with the slots in the hub.
Apply clean grease to the dust seal lip and install the dust seal over the gear retainer.

Fill the speedometer gear box with clean grease and install the drive gear.

Install the speedometer gear box into the wheel hub.

Apply clean grease to the right dust seal lip and install the seal into the wheel.
Install the side collar.

Page 12-12

INSTALLATION

Position the tang on the speedometer gear box against the back of the lug on the left fork leg.

Insert and tighten the axle bolt.

TORQUE: 60 N.m(6.0kg-m, 43 ft-lb)

Tighten the axle pinch bolts.

TORQUE: 22N.m (2.2 kg-m, 16 ft-lb, 192 in-lb)

Install the brake caliper with the caliper bracket.
Install the caliper mounting bolts and tighten the bolts.

TORQUE: 27N.m (2.7 kg-m, 20 ft-lb, 240 in-lb)

Connect the speedomater cable with the set screw.

FORK

REMOVAL

• handlebars (page 12-3).
• front wheel (page 12-7).
• brake caliper (page 14-11).
• mounting bolts and fender.

Loosen the fork top bridge pinch bolts.
If the fork legs will be disassembled, loosen the fork tube caps but do not remove them yet.

CAUTION

• Do not use an adjustable wrench to loosen the fork tube caps, it may damage them.

Loosen the fork bottom pinch bolts and removethe fork legs from the fork top bridge and steering stem.

DISASSEMBLY

WARNING

• The cap is under spring pressure. Use care when removing it and wear eye and face protection.

Drain the oil by pumping the tube up and down several times.

Hold the fork slider in a vise with soft jaws or use a shop towel.

Remove the socket bolt with a hex wrench.

NOTE

• Temporarily reinstall the spring and cap if the bolt is difficult to remove.

Page 12-14

Remove the dust seal and the stop ring with a screwdriver.

CAUTION

• Do not scratch the fork tube sliding surface.

Pull the fork tube out until resistance from the slider bushing is felt. Then move it in and out, tapping the bushing lightly until the fork tube separates from the slider. The slider bushing will be forced out by the fork tube bushing.

Remove the oil lock piece from the piston.
Remove the piston and rebound spring from the fork tube.

Remove the oil seal, back-up ring and slider bushing from the fork tube.

NOTE

• Do not remove the fork tube bushing unless it is necessary to replace it with a new one. See bushing inspection, page 12-15.

Page 12-15

INSPECTION

Replace the spring if it is shorter than the service limit.

Fork tube/slider/piston
Check the fork tube, fork slider and piston for score marks and excessive or abnormal wear.
Replace any components which are worn or damaged.

Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.

Set the fork tube in V blocks and read the runout.
Use 1/2 the total indicator reading to determine the actual runout.

SERVICE LIMIT: 0.20 mm (0.008 in)

Bushings

Visually inspect the slider and fork tube bushings.
Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire surface.

Check the back-up ring; replace it if there is any distortion at the points shown.

Page 12-16

ASSEMBLY

Assemble the rebound spring onto the piston.
Insert the piston assembly into the fork tube.
Place the oil lock piece on the end of the piston and insert the fork tube assembly into the slider.

Place the fork slider in a vise with soft jaws or use a shop towel to avoid damaging the slider.
Clean and apply a locking agent to the socket bolt threads and screw the bolt into the piston.
Temporarily install the fork spring and cap to tighten the socket bolt.
Tighten the bolt with a 6 mm hex wrench.

TORQUE: 17 N.m (1.7 kg-m, 12 ft-lb, 144 in-lb)

Page 12-17

Place the slider bushing over the fork tube and rest it on the slider.

Drive the bushing into place with the seal driver.

Coat a new oil seal with ATF or equivalent and install it with the seal markings facing up. Drive the seal in with the seal driver.

TOOLS:
Fork seal driver	07947‹KA50100
-driver attachment	07947‹KF00100

Install the stop ring securely into the groove in the fork slider.

CAUTION

• Do not scratch the fork tube sliding surface.

Install the new dust seal onto the fork slider.

Compress the fork tube and pour in the recommended fork oil to the specified level.

RECOMMENDED FORK OIL: ATF or EQUIVALENT

SPECIFIED LEVEL: '88: After'88:	133 mm (5.2 in} 128mm )(5.0 in)
CAPACITY: '88: After'88:	497 cc (16.8 US oz, 17.4 Imp oz) 502 cc (16.9 US oz, 17.6 Imp oz)

Gently install the fork spring in the fork tube then install the spring seat and spacer.

NOTE

• Note the spring direction; the tapered end must face toward the bottom.

Loosely install the fork tube cap with a new O-ring.

CAUTION

• Do not damage the fork tube sliding surface.

Page 12-18

INSTALLATION

Apply oil to the lower pinch bolt threads and tighten the bolt.

TORQUE: 50 N.m (5.0 kg-m, 36 ft-lb)

Screw in the upper pinch bolt but do not tighten it.

First, tighten the fork tube cap.

TORQUE: 23 N.m (2.3 kg-m, 17 ft-lb 204 in-lb)

Next, tighten the top pinch bolt to avoid damage the fork cap threads.

TORQUE: 11 N.m (1.1 kg-m, 8ft-lb, 96 in-lb)

install the following:

• fender and brake caliper (page 14-12).
• front wheel (page 12-12).
• handlebars (page 12-5).

Page 12-19

HEADLIGHT BRACKET

REMOVAL

• fuse box stay mounting bolts
• fuse box stay with the box
• headlight bracket and headlight case

HEADLIGHT REMOVAL

INSTALLATION

Insert the bracket upper pins onto the fork top bridge holes completely and hold the bracket in place.

Install the fuse box stay onto the headlight bracket bottom pins and loosely install the mounting bolts into the steering stem.
Tighten the mounting bolts securely.

Page 12-20

STEERING STEM

REMOVAL

• handlebars (page 12-3)
• front wheel (page 12-7)
• steering stem nut cap from the steering stem nut.
• the steering stem nut.

  TOOL:
  Lock nut wrench, 30 x 32 mm 07716 - 0020400
  Equivalent commercially available in U.S.A.

Remove the fork (page 12-12).

Straighten the lock washer tabs and remove the lock nut and lock washer.

Remove the bearing adjustment nut.

TOOL:
Steering stem socket 07916 - 3710100

Remove the dust seal, upper bearing inner race and upper bearing pull the steering stem out of the steering head.

Check the steering stem bearings for damage or wear.

Page 12-21

BEARING REPLACEMENT

• Replace the bearing and bearing races as a set.

Remove the lower bearing inner race and dust seal from the steering stem.

NOTE

• Temporarily install the steering stem nut onto the steering stem when removing the lower inner race.
• Do not damage the steering stem threads.

Removal
Assemble the Race Remover Set parts as shown to remove the outer races from the steering head.

TOOLS:
BALL RACE REMOVER SET (Includes (1) to (6))		07946-KM90001
(1)	DRIVER SHAFT ASSEMBLY (Includes nuts A and B)	07946-KM90300
(2)	ASSEMBLY BASE	07946-KM90600
(3)	DRIVER ATTACHMENT A, 47mm	07946-KM90100
(4)	DRIVER ATTACHMENT B, 55mm	07946-KM90200
(5)	BEARING REMOVER A, 47mm	07946-KM90401
(6)	BEARING REMOVER B, 55mm	07946-KM90500

If the remover set is not available, use the alternate tool:

Adjustable bearing puller   07736-A01000A (U.S.A. only)
with commercially available slide hammer.

Install the ball race remover into the head pipe as shown.

NOTE

• Align bearing remover A (5) with the groove in the head pipe.
• Lightly tighten nut B (1) with a wrench.
• Note the installation direction of the assembly base (2).

Holding the driver shaft (1) with wrench, turn nut A (1) gradually to remove the upper outer race.

Page 12-22

Install the bearing remover as shown and remove the lower outer race using the same procedure as for the upper outer race.

NOTE

• Align bearing remover B (6) with the groove in the head pipe.

Installation
Install a new upper outer race and the ball race remover as shown.
Holding the driver shaft ( 1 ) with a wrench, turn nut A gradually until the groove in driver attachment A aligns with the upper end of the steering head pipe to install the upper ball race.

Page 12-23

Install a new lower outer race and the ball race remover into I the head pipe as shown.
I Holding the driver shaft (1) with a wrench, turn nut A gradually until the groove in driver attachment B aligns with the lower end of the steering head pipe to install the lower outer race.
(1) DRIVERSHAFT, NUT A
(2) ASSEMBLY BASE
(3) DRIVER ATTACHMENT A, 47 mm
(4) DRIVER ATTACHMENT B, 55 mm
(a) WRENCH
(b) LOWER OUTER RACE
(c) UPPER OUTER RACE
(d) GROOVE

If the remover set is not available, use the alternate tools:

Attachment, 42 x 47 mm	07746-0010300
Attachment, 52 x 55 mm	07746-0010400
Driver	07749-0010000

Install a dust seal onto the steering stem and press the lower bearing inner race over the stem with the special tool.

TOOL:
Steering stem driver 07946-MBO0000

INSTALLATION

Install the lower bearing onto the steering stem, then insert the steering stem into the steering head.

Install the upper bearing, upper bearing inner race and dust seal.

Page 12-24

Install and tighten the adjustment nut to the specified torque.

TORQUE: 20 N.m (2.0 kg-m. 14 ft-lb)

TOOL:
Steering stem socket 07916 - 3710100

Turn the steering stem lock-to-lock 4 or 5 times to seat the bearings, then tighten the nut to the same torque.

Install a new bearing adjustment nut lock washer aligning the tabs with the grooves in the nut. Bend two opposite tabs down into the grooves.

NOTE

• Do not install a used lock washer.

Finger tighten the lock nut all the way.
Hold the adjustment nut and further tighten the lock nut (within 90 degrees) enough to align its grooves with the lock washer tabs.
Bend the lock washer tabs up into the lock nut grooves.

Page 12-25

Install the fork top bridge and install the steering stem nut.
Temporarily install the fork legs.
Tighten the steering stem nut.

TORQUE: 105 N.m (10.5 kg-m, 76 ft-lb)

Tighten the bridge pinch bolts.

TORQUE: 11 N m (1.1 kg-m, 8 ft-lb)

TOOL:
Lock nut wrench, 30 x 32 mm	07716-0020400 Equivalent commercially available in U.S.A.

Tighten the fork bottom pinch bolts.

TORQUE: 50 N.m (5.0 kg-m, 36 ft-lb)

Install the steering stem nut cap onto the stem nut.

STEERING HEAD BEARING PRELOAD

NOTE

• Make sure that there is no cable or wire harness interference.

The preload should be within 1.0 - 1.5 kg (2.2 - 3.3 lb) for right and left turns.
If the readings do not fall within the range, lower the front wheel and adjust the bearing adjustment nut.
After making sure the bearing preload is acceptable, install the removed parts in the reverse order of removal.