Slacken the top yoke clamp bolt (A). Fork top bolt (B)

5.10b Ensure lever clamps with UP facingup

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Unscrew the nut (A) and the pivot bolt (B)

the handlebar (see illustration).

d) Make sure the pin in the lower half ofeach switch housing locates in the hole in the handlebar.

e) If removed, apply a suitable non-permanent locking compound to the handlebar end-weight retaining screws. If new grips are being fitted, secure them using a suitable adhesive to the handlebar (left-handgrip) or to the throttle twistgrip (right-hand grip).

f) Tighten all bolts to the torque settings specified at the beginning of this Chapter.

Handlebar levers

Removal - clutch lever

6.5 Slide the fork leg out of the bottom yoke

11Slacken the clutch cable adjuster lockring

5.11a Slacken the lockring (A) and thread In the adjuster (B)...

and thread the adjuster fully into the bracket to provide maximum freeplay in the cable (see illustration).Unscrew the lever pivot bolt locknut, then withdraw the pivot bolt and remove the lever, detaching the cable nipple as you do so (see illustration).

Removal - brake lever

12Unscrew the lever pivot bolt locknut, then
withdraw the pivot bolt and remove the lever
(see illustration).

Installation

13Installation is the reverse of removal.
Apply grease to the pivot bolt shafts and the
contact areas between the lever and its
bracket, and to the clutch cable nipple. Adjust
the clutch cable freeplay (see Chapter 1).

Removal

Caution: Although not strictly necessary, before removing the forks it is recommended that the fairing (SW, SX and SY models) and radiator side panels (R, T, V, W, X and Y models) are removed (see Chapter 8). This will prevent accidental damage to the paintwork.

1 Remove the front wheel (see Chapter 7) and the front mudguard (see Chapter 8).

2 Remove each fork leg individually.

3 Unscrew the bolts securing the front brake caliper bracket to the right-hand fork slider and remove the caliper. Secure the caliper to the bike with a cable tie to ensure no strain is placed on the hydraulic hose. Discard the caliper bracket bolts as new ones must be fitted on reassembly (see Chapter 7).

4 Slacken but do not remove the fork clamp bolt in the top yoke (see Illustration).If the fork legs are going to be disassembled or the fork oil is going to be changed, slacken the fork top bolt while the leg is still clamped in the bottom yoke.

5 Slacken but do not remove the fork clamp bolt in the bottom yoke and remove the fork leg by twisting it and pulling it downwards (see illustration).

Frame, suspension and final drive 6»7

7.1 Front fork components 8 Rebound spring 9 Fork tube 10 Bottom bush 11 Dust seal 12 Retaining clip 13 Oil seal 14 Washer

15 Top bush 16 Damper rod seat 17 Fork slider 18 Sealing washer 19 Damper rod bolt 20 Axle clamp bolt 21 Oil drain screw - R model

fork, it may be necessary to re-install the spring, spring seat, spacer and top bolt to prevent the damper rod from turning. Alternatively, a long metal bar passed down through the fork tube and pressed hard into the damper rod head quite often suffices. 8 Withdraw the damper rod from inside the fork tube. Remove the rebound spring from the damper rod (seeillustration).

7.8 Withdraw the damper rod and rebound spring from the tube

IM3

HiWT

Date: 2016-01-14; view: 679

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