Page 13-1

SERVICE INFORMATION	13-1
TROUBLESHOOTING	13-2
REAR WHEEL	13-3
SPROCKET	13-6
ECCENTRIC BEARING CARRIER REMOVAL	13-6
BEARING REPLACEMENT	13-9
SPINDLE	13-11
ECCENTRIC BEARING CARRIER INSTALLATION	13-12
SHOCK ABOSORBER	13-14
SWINGARM	13-19
MUFFLER/EXHAUST PIPE	13-24
SEAT	13-25
REAR COWLING	13-25

SERVICE INFORMATION

GENERAL

Never ride on the rim.
When using a lock nut wrench, use a 20 inch long deflection bea type torque wrench. The lock nut wrench increases the torque wrenche’s leverage, so the torque wrench reading will be less than the torque actually applied tothe lock nut.

WARNING

A contaminated brake disk or pad reduces stopping power. Discard contaminated pads and clean a contaminated disk with a high quality brake degreasing agent.
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.
The shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the shock abosrber.
Before disposal of the shock absorber, release the nitrogen. (see page 13-16)

SPECIFICATIONS

Unit: mm (in)

ITEM		STANDARD	SERVICE LIMIT
Rear wheel rim runout	Radial	—	2.0 (0.08)
Rear wheel rim runout	Axial	—	2.0 (0.08)
Shock absorber spring free length		—	148.3 (5.84)
Shock absorber spring preload adjuster position		3	—
Compression force qt 10 mm (0.4 in) compressed		15-20 kg (33.1-44.1 lb)	14.9 kg (32.8 lb)

TORQUE VALUES

Sprocket mounting bolt	43 N•m (4.3 kg-m, 31 ft-lb)
Brake disk retaining bolt	35 N•m (3.5 kg-m, 25 ft-lb)
Brake disk retaining bolt lock nut	9 N•m (0.9 kg-m, 7 ft-lb, 84 in-lb)
Rear wheel nut	120 N•m (12.0 kg-m, 87 ft-lb)
Eccentric bearing carrier pinch bolt	75 N•m (7.5 Kg-m, 54 ft-lb)
Shock absorber mounting bolt: upper side	65 N•m (6.5 kg-m, 47 ft-lb)
Shock absorber mounting bolt: lower side	54 N•m (4.5 kg-m, 33 ft-lb)
Damper rod lock nut	62 N•m (6.2 kg-m, 45 ft-lb) Apply a locking agent to the threads
Swingarm pivot nut	65 N•m (6.5 kg-m, 47 ft-lb)
Swingarm pivot lock nut	65 N•m (6.5 kg-m, 47 ft-lb)
Swingarm pivot adjusting bolt	15 N•m (1.5 kg-m, 11 ft-lb, 132 in-lb)
Brake torque rod bolts	35 N•m (3.5 kg-m, 25 ft-lb)
Sub-frame mounting bolts	40 N•m (4.0 kg-m, 29 ft-lb)
Fuel filter base mounting bolt	22 N•m (2.2 kg-m, 16 ft-lb, 192 in-lb)
Eccentric bearing carrier lock nut	165 N•m (16.5 kg-m, 120 ft-lb) Staked nut

TOOLS

Special
Snap ring pliers	07914—323000 — Equivalent commercially available in the U.S.A.
Shock absorber compressor attachement	07967—KE10000
Driver shaft	07946—MJ00000
Bearing remover set	07946—MJ00200
— Driver head	07946—KA30200 Not available in the U.S.A.
Spherical bearing driver	07908—ME90000
Lock nut wrench	07965—KE80100
Oil seal driver	07965—KE80100

Common
Driver	07749—0010000
Attachment, 24 x 26 mm	07746—0010700
Attachment, 32 x 35 mm	07746—0010100
Attachment, 42 x 47 mm	07746—0010300
Attachment, 52 x 55 mm	07746—0010400
Attachment, 62 x 68 mm	07746—0010500
Pilot, 15 mm	07746—0040300
Pilot, 17 mm	07746—0040400
Pilot, 20 mm	07746—0040500
Pilot, 22 mm	07746—0040000
Pilot, 35 mm	07746—0040700
Pilot, 40 mm	07746—0040700
Driver handle	07949—3710001

TROUBLESHOOTING

Wobble or vibration in motorcycle

Bent rim
Loose wheel hub bearing(s)
Damaged tire
Axle not tightened properly
Swingarm bearing pivot worn
Bent frame or swingarm
Damaged drive pin and pin hole

Soft suspension

Weak spring
Improper shock absorber spring preload
Leaking damper

Hard suspension

Improper shock absorber spring preload
Bent shock abosrober rod
Swingarm pivot bearings damaged
Bent frame or swingarm

Suspension Noise

Faulty rear damper
Loose fasteners

REAR WHEEL

REMOVAL

WARNING

Do not service the rear wheel (removal/installation) while exhaust system is hot.

CAUTION

Cover the left rim edge, spindle edge and brake caliper with tape to avoid damaging the wheel.

NOTE

The sprocket and driven flange dampers can be removed without removing the wheel (see page 13-6).

Place the motorcycle on its center stand.
Remove the center cap and cotter pin. Loosen the wheel nut, but do not remove it.

Info: The rear wheel mounting nut is 27mm.

Loosen the eccentric bearing carrier pinch bolt and turn the carrier counterclockwise until it stops to obtain maximum chain slack.
Remove the chain from the rear sprocket and place it on the outside of the sprocket.
Rotate the eccentric bearing carrier to its rearward most (maximum chain slack) position.

Remove the wheel nut, shim and axle center collar.

Tap the axle with soft hammer and push the axle in until it clears the wheel.

Attach tape to the wheel rim, edge of the spindle and brake caliper to avoid damaging the wheel.

Remove the wheel from the drive pins, then angle it to the right and pull it backward to go between the brake disc and muffler.

CAUTION

Be careful not to damage the wheel rim and brake disc when removing the wheel.

Then, as the wheel reaches the hub, angle it to the left and pull it out backward as shown.

CAUTION

Be careful not to damage the wheel rim and brake caliper when removing the wheel.

Page 13-4

INSPECTION

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)

NOTE

The wheel cannot be repaired and must be replaced with a new one if the service limits are exceeded.

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 (a paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary.

Remove the dust seal from the wheel.
Mount the wheel and tire 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 position.

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 rear wheel.

Drive pin hole

Check the drive pin holes for the damage.

Inspection and replacement of the drive pin: turn to page 13-11.

Page 13-5

INSTALLATION

WARNING

Do not service the rear wheel (removal/installation) while exhaust system is hot.

CAUTION

Cover the left rim edge, spindle edge and brake caliper with tape to avoid damaging the wheel.
Use care not to damage the wheel rim and brake disc when removing the wheel.

Install the rear wheel in the reverse order of removal.

Clean the wheel and spindle mating surface.
Align the index marks and install the wheel hub over the drive pins.

Insert the axle in the wheel hub, making sure the splines are correctly aligned.

Tap the axle with soft hammer to seat the axle securely.

Turn the eccentric bearing carrier counterclockwise until it stops.
Install the drive chain onto the rear sprocket.

Clean and apply clean grease to the axle threads.

CAUTION

Make sure that the axle threads are applied clean grease to obtain the specified torque.

Install the axle center collar, shim and wheel nut.
Tighten the wheel nut to the specified torque.

TORQUE: 120 N•m (12.0 kg-m, 87 ft-lb)

Install a new cotter pin and cap securely.

Apply the rear brake several times and check for free wheel rotation when released.

Adjust the drive chain slack (page 3-12).

Page 13-6

SPROCKET

REMOVAL

Turn the eccentric bearing carrier to loose the drive chain, then remove the chain from the sprocket.

Remove the sprocket mounting bolts and the sprocket.

INSTALLATION

Install the sprocket by using the bolts and nuts.

TORQUE: 43 N•m (4.3 kg-m, 31 ft-lb)

Reinstall the drive chain and adjust the slack (page 3-12).

ECCENTRIC BEARING CARRIER

REMOVAL

Remove the rear wheel (page 13-3).
Loosen the eccentric bearing carrier pinch bolt and turn the carrier to loosen the drive chain.

Tap the axle with a soft hammer until the splines clear the driven flange cover.

Remove the axle to the left side.

Page 13-7

Unstake the eccentric bearing carrier lock nut and remove the nut.
Remove the lock washer and side collar.

Info: The nut is 46mm. A 1-13⁄16" socket is exactly the same size but easier to find and cheaper.

Remove the brake caliper mounting bolts.
Swing the brake caliper from the brake disc while holding it with a piece of wire or something suitable.

Remove the spindle.
Remove the final driven flange assembly and remove the drive chain from the sprocket.

Remove the snap ring and brake disc guard plate.
Remove the eccentric bearing carrier from the swingarm.

Page 13-8

INSPECTION

Bearing
Turn the inner races of the ball bearings with your finger.
The bearing should turn smoothly and quietly.

Also check that the bearing outer races fits tightly in the eccentric bearing carrier.
Check the right bearing needle rollers for obvious signs of wear.

Remove and discard the ball bearings if they do not turn smoothly, quietly, or if they fit loosely in the eccentric bearing carrier (page 13-9).

NOTE

Replace the bearings in pairs.

Replace the needle bearing if it is damaged.

Damper
Separate the driven flange cover with the sprocket from the flange.

Check the driven flange damper for damage.
Replace the dampers if necessary.

Page 13-9

BEARING REPLACEMENT

Eccentric bearing carrier
Remove the dust seals and bearing stop rings.

Press the ball bearings out of the carrier first with the special tools.

TOOLS:
Driver	07749—0010000
Attachment, 42 x 47 mm	07746—0010300
Pilot 40 mm	07746—0040900

Press the needle bearing out of the carrier with the special tools.

TOOLS:
Driver	07749—0010000
Attachment 52 x 55 mm	07746—0010400

Install the inner dust seal in the carrier.
Carefully press the new needle bearing into the carrier first with the special tools.

NOTE

Install the bearing with marks facing out.

TOOLS:
Driver	07749—0010000
Attachement 62 x 68 mm	07746—0010500

Page 13-10

Apply clean grease to the dust seal lip.
Install the bearing stop ring and dust seal securely.

Carefully press the new ball bearings in with the special tools.

NOTE

Install the bearing with sealed end facing out.

TOOLS:
Driver	07749—0010000
Attachment 62 x 68 mm	07746—0010500

Apply clean grease to the dust seal lip.
Install the bearing stop ring and dust seal securely.

Driven flange
Separate the cover and the flange.
Remove the dampers and the O-ring.

Page 13-11

Press the bearing and dust seal out of the cover with the special tools.

TOOLS:
Driver	07749—0010000
Attachment 52 x 55 mm	07746—0010400
Pilot 35 mm	07746—0040800

Carefully press the new bearing in with the special tools.

TOOLS:
Driver	07749—0010000
Attachment 62 x 68 mm	07746—0010500
Pilot 35 mm	07746—0040800
Oil seal driver	07965—KE80100

Install the dust seal securely.

SPINDLE

INSPECTION

Check the following of the spindle:

splines for damage
drive pins for damage
lock nut threads for damage

If necessary, remove the brake disc retaining bolts and nuts and lock nut, and separate the brake disc from the spindle.

Apply a locking agent to the drive pin bolt threads and tighten the drive pin bolts to the drive pin if replaced them.

TORQUE: 15 N•m (1.5 kg-m, 11 ft-lb)

Install the brake disc to the spindle and tighten the disc retaining bolts and nuts.

TORQUE: 35 N•m (3.5 kg-m, 25 ft-lb)

Install the disc retaining bolt lock nut onto the anywhere bolt.

TORQUE: 9 N•m (0.9 kg-m, 7 ft-lb)

Page 13-12

ECCENTRIC BEARING CARRIER INSTALLATION

Install the eccentric bearing carrier onto the swingarm.
Loosely install the eccentric bearing carrier pinch bolt.

Install the brake disc guard plate onto the eccentric bearing carrier by using the snap ring.

Page 13-13

Install the drive chain on the sprocket and position the flange against the eccentric bearing carrier.

Insert the spindle through the bearing carrier and driven flange. Engage the driven flange and the spindle, making sure the splines are correctly mated.

CAUTION

Use care not to damage the pads when installing the caliper.

Install over the brake caliper onto the brake disc.
Install and tighten the mounting bolts.

TORQUE: 27 N•m (2.7 kg-m, 20 ft-lb)

Install the rear axle from the left side.

Install the side collar onto the driven flange.

Install the lock washer onto the spindle as shown.

Install the eccentric bearing carrier lock nut and stake it.

TORQUE: 165 N•m (16.5 kg-m, 120 ft-lb)

Page 13-14

Install the rear wheel (page 13-5).
Adjust the drive chain slack (page 3-12).

Tighten the eccentric bearing carrier pinch bolt.

TORQUE: 75 N•m (7.5 kg-m, 54 ft-lb)

Operate the brake pedal to seat the caliper piston against the pads.

SHOCK ABSORBER

WARNING

The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber.
Before disposal of the shock absorber, release the nitrogen.

NOTE

If you plan to disassemble the shock absorber, set the spring adjuster to the softest position at this time.

REMOVAL

Raise the rear wheel off the ground by placing the motorcycle on its center stand.

Remove the seat (page 13-25).
Remove the shock absorber lower mounting bolt while supporting the wheel.

Remove the following:

sub-frame upper mounting bolts
shock absorber upper mounting bolt and nut
fuel filter base mounting bolt and nut
fuel filter base

Loosen the sub-frame lower mounting bolts and lower the subframe.

Pull the shock absorber out from the frame through the upper sub-frame pipes.

Remove the shock absorber lower mounting collar.

Page 13-15

DISASSEMBLY

Make sure the spring adjuster is set to the softest position before disassembly.
Set the shock absorber in the hydraulic press with the special tool.

TOOL:
Shock absorber compressor attachement	07967—KE10000

Compress the spring until the stop ring can be removed, and remove the stop ring from the shock absorber.

Remove the following:

upper spring seat
spring
lower spring seat
spring adjuster
dust seal
lock nut and lower joint
stop rubber
seat

INSPECTION

Inspect the following parts:

damper unit for oil leaks
damper rod for bends or damage
stop rubber for wear or damage

Inspect all the other parts for wear or damage.

Measure the spring free length.

SERVICE LIMIT: 148.3 mm (5.84 in)

Page 13-16

Mark the 10 mm position on the damper rod as shown.
Place the damper rod on a scale and measure the force required to compress the damper to the 10 mm (0.4 in) mark.

COMPRESSION FORCE: 15 - 20 kg (33.1 - 44.1 lb)

If the force required is less than 14.9 kg (32.8 lb), gas is leaking.
Examine the damper rod and replace the damper unit if it is bent or scored.

SHOCK ABSORBER DISPOSAL PROCEDURE

Center punch the damper case to mark the drilling point, approximately 15 mm (0.59 in) from the top surface.
Wrap the damper unit inside a plastic bag.
Support the damper unit upright in a vise as shown.
Through the open end of the bag, insert a drill motor with a sharp 2-3 mm (5/64 - 1/8 in) drill bit.

WARNING

Do not use a dull drill bit which could cause a build-up of excessive heat and pressure inside the damper, leading to explosion and severe personal injury.
The shock absorber contains nitrogen gas and oil under high pressure. Do not drill any farther down the damper case than the measurement given above, or you may drill into the oil chamber; oil escaping under high pressure may cause serious personal injury.
Always wear eye protection to avoid getting metal shavings in your eyes when the gas pressure is released.
The plastic bag is only intended to shield you from the escaping gas.

Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start.

ASSEMBLY

Apply locking agent to the rod threads and install the lock nut.
Screw in the lock nut fully.
Install the seat.
Screw the lower joint onto the damper rod fully, hold it and tighten the lock nut.

TORQUE: 62 N•m (6.2 kg-m, 45 ft-lb)

NOTE

Align the tabs of the seat with the lower joint.

Page 13-17

Install the following:

stop rubber onto the damper rod
spring guide
spring adjuster, set to the softest position
dust seal
lower spring seat
spring with the tapered end upward
upper spring seat

Install the shock absorber drain tube on the seat.

Make sure the tab of the seat is aligned with the groove of the spring guide.

NOTE

Make sure the spring adjuster is set to the softest position.

Set the shock absorber in the hydraulic press with the special tool.

TOOL:
Shock absorber compressor attachment	07967—KE10000

Compress the spring until the stop ring can be installed, and install the stop ring.

Page 13-18

LOWER MOUNTING BEARING REPLACEMENT

Remove the dust seals from the lower mount.
Press the needle bearing out of the shock absorber with the special tool.

TOOL:
Spherical bearing driver	07946—KA30200 Not available in U.S.A.

Apply clean grease to a new needle bearing and drive it into the shock absorber until it is flush with lower mount surface.

TOOLS:
Driver	07749—0010000
Attachment 24 x 26 mm	07746—0010700
Pilot 17 mm	07746—0040400

Apply clean grease to the dust seal lips and install them onto the lower mount.

INSTALLATION

Install the lower mounting collar into the mount.
Install the shock absorber in the frame with the drain tube facing forward.
Tighten the shock absorber upper mounting bolt.

TORQUE: 65 N•m (6.5 kg-m, 47 ft-lb)

Install the fuel filter base and mounting bolt.

TORQUE: 22 N•m (2.2 kg-m, 16 ft-lb)

Install the sub-frame upper mounting bolts.

TORQUE: 40 N•m (4.0 kg-m, 29 ft-lb)

Tighten the sub-frame lower mounting bolts.

TORQUE: 40 N•m (4.0 kg-m, 29 ft-lb)

Page 13-19

Route and clamp the shock absorber drain tube.
Install the shock absorber lower mounting bolt.

TORQUE: 45 N•m (4.5 kg-m, 33 ft-lb)

SWINGARM

REMOVAL

Raise the rear wheel off the ground by placing the motorcycle on its center stand.
Remove the rear wheel (page 13-3) and eccentric bearing carrier (page 13-6).

Remove the shock absorber lower mounting bolt.

Remove the swingarm pivot nut.

Unhook the rear brake hose and remove the rear brake caliper (page 14-15).

Loosen the lock nut and remove it.
Do not pull the swingarm pivot bolt out at this time.

TOOL:
Lock nut wrench	07908—ME90000

Using a hex wrench, turn the pivot bolt and adjusting bolt counterclockwise together.

Page 13-20

Pull the pivot bolt out the frame while supporting the swin-arm.

Remove the swingarm from the frame.

Remove the pivot collars and bushing.

DISASSEMBLY

Remove the following components:

drive chain slider
driven sprocket guard plate
brake disc guard plate
brake torque rod
shock absorber drain tube clamp
brake hose clamp

PIVOT BEARING REPLACEMENT

Remove the dust seals from the swingarm.
Remove the snap ring from the right side.

Page 13-21

Press the right pivot bearings out of the swingarm using a hydraulic press and the driver shaft.

TOOL:
Driver shaft	07746—MJ00100 or
Driver handle	07949—3710001

Press the left pivot needle bearing out of the swingarm using a hydraulic press and the special tool.

TOOL:
Driver shaft set	07746—MJ00000

Apply clean grease to the new pivot bearings.
Press the right pivot bearing into the swingarm until it is flush with the surface.

TOOLS:
Driver	07749—0010000
Attachment, 32 x 35 mm	07746—0010100
Pilot, 15 mm	07746—0040300

Apply clean grease to the pivot needle bearing.
Press the left needle pivot bearing into the swingarm until it is flush with the surface.

TOOLS:
Driver	07749—0010000
Attachment, 32 x 35 mm	07746—0010100
Pilot, 22 mm	07746—0041000

Page 13-22

Install the snap ring into the groove in the swingarm.
Apply clean grease to the dust seal lips and install the dust seals in the swingarm pivots.

ASSEMBLY

Install the following components:

drive chain slider
driven sprocket guard plate
brake disc guard plate
shock absorber drain tube clamp
brake hose clamp

Install the brake torque rod with a new cotter pin.

TORQUE: 35 N•m (3.5 kg-m, 25 ft-lb)

INSTALLATION

Install the pivot collars and bushing in the swingarm.

Loosely install the pivot adjusting bolt then install the swingarm to the frame.
Insert the pivot bolt through the adjusting bolt fully.

Page 13-23

Turn the pivot bolt and adjusting bolt together clockwise until they touch the left pivot collar.
Tighten the adjusting bolt.

TORQUE: 15 N•m (1.5 kg-m, 11 ft-lb)

Loosely install the lock nut.
Tighten the lock nut while holding the adjusting bolt and pivot bolt.

TORQUE:
	Actual:	65 N•m (6.5 kg-m, 47 ft-lb)
	Indicated:	59 N•m (5.9 kg-m, 43 ft-lb)

TOOL:
Lock nut wrench	07908—ME90000

Install the pivot nut and tighten to the specified torque.

TORQUE: 65 N•m (6.5 kg-m, 47 ft-lb)

Install the following:

eccentric bearing carrier (page 13-12).
rear brake caliper (page 14-17).
shock absorber lower mounting bolt (page 13-19).
rear wheel (page 13-5).

Page 13-24

MUFFLER/EXHAUST PIPE

Removal

WARNING

Do not service the exhaust system while it is hot.

Remove the following:

four joint nuts
two mounting bolts
exhaust pipe and muffler as assembly.

Loosen the exhaust pipe band bolt and separate the muffler and exjaust pipes.

INSTALLATION

Installation is in the reverse order of removal

Install the exhaust pipe as an assembly.

TORQUE:
	Exhaust pipe joint nut:	27 N•m (2.7 kg-m, 20 ft-lb)
	Muffler mounting bolt:	27 N•m (2.7 kg-m, 20 ft-lb)
	Muffler band bolt:	27 N•m (2.7 kg-m, 20 ft-lb)

CAUTION

Be sure the new exhaust pipe gaskets are correctly seated on the pipe flange before installing the pipes.

Page 13-25

SEAT

REMOVAL/INSTALLATION

Insert the ignition key into the helmet holder and turn it clockwise.
Pull the holder hook down to realease the seat lock.
Remove the Seat from the frame.
Installation is the reverse order of removal.

NOTE

Apply clean greas to the seat lock striker and latch.

REAR COWLING

REMOVAL/INSTALLATION

Remove the seat.
Disconnect the tail/brake and turn signal light wire harnesses connectors.
Remove the four rear cowling mounting bolts and the cowling.
Installation is the reverse order of removal.