FINAL DRIVE INSTALLATIO N

⇐ ПредыдущаяСтр 16 из 19Следующая ⇒

Apply multipu rpose grease to the pin ion jo int splines and drive shaft oil seal.

I nsert the drive shaft in to the swingarm and align its splines with the u niversal jo int.

(1) STOP RING (2) OIL SEAL

I nstall the gear case and drive shaft into the swing

Arm.

NOTE

Attach the gear case onto the swingarm loosely.

NOTE

Install the rear wheel Cpage 16-7). Tighten the axle nut.

TORQUE : 50-80 N·m

(5.0-8,1() kg-m, 36-8ft-lbl Tighten the axle pinch bolt.

TORQUE: 20-30 N·m

(2.0-3.() kg-m, 114-22 ft-lb)

Tighten the four final gear case attaching nu ts.

TORQUE:20-24 N·m

(2.0-2.4 kg-m, 14-18 ft·l b) Install the left shock absorber ( page 16·12).

Place the motorcycle on i ts cen ter stand. Make sure that the drain bolt is tightened.

Remove the oil filler cap and pour the specif ied amou nt of recom mended oil up to the filler neck.

RECOMMENDED OIL: HYPOID GEAR OllL

Over 5°C: SAE 90 Below 5°C: SAE 80

OIL CAPACITY: 150 cc (5.1oz)

(3) DRAIN BOLT

20-30 N·m

(2.0-3.0 kg m, 14-22 ft lb)

15-30 N·m

--(1.5-3.0 kg-m,

11-22 ft lb)

18-28 N·m (1.8-2.8 kg m,

13-20 ft-lb)

45-55 N·m

(4.5-5.5 kg m,

33-40 ft-lb)

55-65 N·m (5.5-6.5 kg m,

40-47 ft lb)

18-28 lll·m

(1.8-2.8 kg·m,

13-20 ft·lb)

30-40 N·m

(3.0-4.0 kg m,

25-29 ft·lb)

FRONT WHEEL/SUSPENSION

VT500C

H EADLIG HT

CASE REMOVA L

Remove the headlight mounting screw.

Disconnect the wire coupler and remove the head· ligh t.

To remove the headlight case, unscrew the headlight case mounts.

(2) SCREW

BULB REPLACEMENT

Remove the clip and head light bulb .

Install a new headlight bulb and install the clip .

CAUTION

WIRING CONNECTIONS IN HEADLIGHT CASE

Route the wires into the headlight case through the headlight case hole.

Connect the color-coded wires and couplers.

(1) HEADLIGHT BULB (2) CLIP

CASE INSTALLAT ION

Align the index marks on the headlight .case stays with the index marks on the brackets.

BRACKET R EMOVAL/ INSTALLAT ION

Remove the headligh t case.

Remove the headlight bracket bolts and bracket/ turn signal assembly.

Install the headlight bracket in the reverse order of removal.

I NSTRUMENTS

Remove the headlight case.

Remove the fork cover and electrical junction box from the steering stem.

Remove the brown coupler from the ju nction box.

BROWN D

{3)

COUPLER c::JD D

(1) INDEX MAR KS

(1) FORK COVER

R emove the speedometer and tachometer cables from the instruments.

Remove the instrument mounti ng nuts and instru ments.

DISASSE MBLY

Remove the instrument lower cover mounting screws and lower cover.

Remove the instrument bracket mounting screw and bracket .

(1) TACHOMETER CABLE

(2) SPEEDOMETER CABLE

(1) LOWER COVER

Remove the instru ment bulbs and replace any burnt out bul bs.

After installing a new bulb, check to be sure it lights.

I f the bulb doesn't light, inspect the wiri ng for an open or short circuit.

Remove the meter setting screws and meter.

Replace the bulb.

I f a replacement bulb does not light, check the wi r· ing for an open circuit or loose connections.

(2) BULB

(1) BULB

(1) SCREWS

(1) BULB SOCKETS

ASSEMBLY/INSTALLATION

Lubricate the speedometer and tachometer cables before reconnecting .

Reassemble and install in the reverse order of re·

moval and disassembly. ...

HANDLEBAR SWITCH REPLACEMENT

NOTE

R emove the handlebar switch mounting screws and throttle cables.

Disconnect the switch wi res from the switch.

Remove the headlight case, fork -cover and junction box.

Disconnect the righ t handlebar switch coupler

!Natural) from the junction box and remove the switch.

I nstall a new switch aligning the switch pin with the hole in the handlebar. Tighten the forward screw first, then tighten the rear $Crew. Check the opera· tion of the switch.

After i nstall i ng, adjust th rottle cable free play (page 3·5).

H ANDLEBARS

REMOVAL

Remove the harness wire bands.

Remove the headlight case {page 15 3), fork cover and junction box (page 15-4).

Disconnect the brake light switch wires and remove the two screws on the switch housing.

Remove the brake master cylinder.

CAUTION

NOTE

Do not loosen the brake hose u nless necessa ry.

(2) PIN

Disconnect the clutch switch wires and remove the two screws on the switch housing.

Remove the choke lever holder and disconnect the choke cable from the chock lever.

Remove the tour caps and handlebar holder mou nt· ing bol ts.

Remove the hand lebar holders and handlebar.

INSTALLATION

Place the handlebar on to the lower holder align ing the punch mark wi th the oUt$ide face of the lower holder.

I nstall the upper holder and 1igh ten the forward bolts first, then tighten the rear bolts.

TORQUE: 20-30 N·m

(2.0-3.0 kg m, 14-22 ft·lbl

FRONT WHEEL /S USPENSION

Apply grease to the throttle grip sliding surface and slide the throttle grip over the handlebar.

I nstall the front brake master cylinder wi th the 'UP' mark on the holder facing up. Align the end of the holder wirh the handlebar punch mark.Tighten the upper bolt first. then the lower bolt.

Install the right handlebar switch and connect the brake light swit<:h wires (page 15-7).

Connect the choke cable to the choke lever and install the clutch master cylinder. Align the end of the holder with the punch mar k on the handlebar.

Tighten the upper bolt first, then the lower bolt. I nstall the left handlebar switch and connect the clutch switch wires (page 158).

H O NDA

VTSOOC

(2) "UP" MAR K

FRONT WHEEL/SUSPENSION

H ONDA

VT500C

CHOKE CABLE REPLACEMENT

Remove the choke lever holder and disconnect the choke cable from the choke lever.

Remove the fuel tank ( page 4-J4).

Remove the choke cable boots and loosen the choke valve nuts on the carburetors.

Remove the choke val ve from the carburetor.

Remove the choke cable from the choke valve. Lubricate the new choke cable.

THROTTLE CABLE REPLACEMENT

Remove the righ t handlebar switch housing (page

15- 7).

Remove the th rottle cables from the th rottle grip.

(1) CHOKE CABLE

(1) THROTILE CABLES

Remove the throttle linkage cover.

Remove the throttle cables fTom the carburetor throttle pulley.

Attach new cables to the throttle pulley. Reinstall the throttle linkage cover.

Route the new cables correctly (page 1-9). Attach the cables to the th rottle grip.

Reinstall the switch housing ( page 15-8). Adjust the th rottle free play (page 3-5).

IG N ITIO N SWIT C H

REMOVAL/ INSTA LLATION

Remove the headlight and headlight case.

Remove the fork cover ju nction box-and two white couplers from the junction box (page 1- 11).

Remove the ignition switch mounting bolts, and ignition switch.

Install the ignition switch in the reverse order of re moval.

DISASSEMBLY/ASSEMBLY

Bend the wire clamp tongue u p.

(1) IGNITION SWITCH

(1) WI R E CLAMP

Insert tht ignition key and tu rn it to between the ON and OFF detent positions.

Push In the lugs In the slots and pull the contact

Base from the switch.

(1) SLOTS

Assemble the ignition switch in the reverse order of disassembly.

•

		.
•,

.. . '

(2) LUGS

FUSE HOLDER

REMOVAL/INSTALLATION

Remove the headlight and nead light case.

Remove the fork co\er and junct ion box from the steering steem. Disconnect the fuse holder coupler from the junction box (page 1-11).

Remove the fuse holder cover mounting screws and the cover .

Remove the fuse holder from the hendle bar upper holder.

I nstall a new holder. route the wire harness and

attach i t to the junction box . Reinstal l the removed parts.

FRO N T WHEEL

REMOVAL

R aise the front wheel off the ground by placing a

support block under the·engine.

Disconnect the speedometer cable by removing the speedometer cable set screw.

CABLE

Remove the axle pinch bolt.

Loosen and remove the front axle and remove the front wheel.

NOTE

DISASSEMBLY

Remove the brake disc mounting bolts and discs.

Remove the side collar and right seal.

{2) SEAL

Remove the left seal and speedometer gear retainer.

{ 11 SEAL

(2) SPEEDOMETER GEAR RETAINER

I nstall the bearing remover collet, 15 mm into the bearing.

Drive the bearing remover expander into the collet from the other side of the bearing.

Stand the wheel up and drive out the bearing from the hub.

NOTE

If the bearings are removed, they should be replaced with new ones.See inspection on the next page.

(1) BEARI NG R EMOVER COLLET, 15mm 07746-0050400

(1) BEARIN G R EMOVER EXPANDER

07746-0050100

INSPECTION WHEEL BEARING

Check wheel bearing play by placing the wheel i n a truing stand and spinning the·wheel by hand.

Replace the bearings if they are noisy or have exces- sive play. '

SERVICE LIMIT:0 03 mm (0.001in)

WH EEL

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

SERVICE L MITS:

RADIA L RUNOUT: 2.0 mm (0.08 in)

AXIA L RUNOUT: 2.0 mm (0.08 in)

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

AX LE

Set the axle in V blocks and measure the runout. The actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT: 0.2 mm (0.01lnl

ASSEMBLY

Do not get grease on the brake disc or stop ping power will be reduced.

NOTE

The cast wheel has no rim band.

The front wheel uses a tubeless tire. For tubeless tire repa ir, refer to the Honda Tubeless Tire Manual.

(1) DRI VER

Drive in the right beari ng first and press th e distance colla r into place.

NOTE

Be certain the distance collar is in position before installi ng the right beari ng.

Drive in the left bearing squarely. NOTE

Pl LOT, 15mm 07746-0040300

Install the speedometer gear retainer into the wheel hub, aligning the tangs with the slots.

Install the left seal.

Install the right seal and side liar.

Apply oll to the brake disc bol t threads.

I nstall the brake disc and tighten the bolts to the specified torque value .

TORQUE:35-40 N·m

.3.5-4.0 kg-m, 25-29 ft-lbl

UTION:

NOTE

Remove the dust seal and speedometer gear box from the wheel.

Mount the wheel, tire and brake disc assembly in an

inspection stand.

Spin the wheel, a llow it to stop, and mark the lowest (heaviest) pa rt 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 nough weigh t so the wheel will no longer stop in the same position when it's spun. Do not add more than 60 gra ms.

INSTALLATION

I nstall the speedometer gearbox in the wheel hub,

-liyning the tabs with the slotS.

Clean the brake discs with a igh quality degreasing agent.

Place the wheel bet'Nff n the fork legs. Fit the disc

carefully between me brake pads.

Align the speedometer 119arbo with the boss on the left fork leg as shown.

I nstall the axle and collar. Remove the support block f rom under the engine.

Tighten the axle to tne spe<:ified torq ue.

TORQUE:55-65 N m

(5.5-6.5 kt-m.4G-47 ft-lb)

Tighten the axle pinch bolt to the specified torque.

TORQUE:18-28 N·m

(1.8-2.8 kg·m, 13-20 ft-lb)

lnstell the speedometer cable and set screw.

(1) SPEEDOM ETER GEAR BOX

FRONT FORKS

Remove the front wheel (page 15-141. Remove the brake caliper bracket.

Remove the front fender and fork brace.

Loosen the fork upper and lower pinch bolts.

Pull the fork tubes down and out while twisting to remove them .

(1) BRAKE CALIPER BOLTS

(21 CAP (3) FORK BRACE

DISASSEMBLY

Depress the air valve and release front fork air pres

Sure.

CAUTION

Drain the fork oil by removing the drain plug.

Hold the fork tube i n a vise with soft Jaws or a shop towel and remove the fork tube cap.

CAUTION

IDo not damage the sli ding surface.

(1) DRAIN PLUG

Remove the collar, washer and fork spring. Pour the fork fluid out.

Pour the remaining fork fluid out by pumping the fork tube several times.

Hold the fork sl der in a vise with soft jaws or a shop towel. Remove the socket bolt with a hex wrench.

NOTE

Temporarily install the spring and fork cap if the bolt is difficult to remove.

Remove the dust seal, foam washer,plastic washer and snap ring.

(11 SNAP RING PLIERS 07914-3230001

(2) SNAP RING

Pull the fork tube out un til resistance from the slider bushi ng Is felt. Then move it in and out, tipping the bushi ng lightly until the fork tube separates from the 1lider. Tne slider bushing will be forced out by the fork tube bushing.

Remove the oil lock piece from inside the slider.

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

NOTE

BUSHING

INSPECTION

FOR K SPRING F REE LENGTH

Measure the fork spring free length.

SERVICE LIMIT:447 mm (17.6 in)

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

: ! .:

15-25

Check the fork tube, fork slider and piston for score marks, scr.atches, or exoessive 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:0.2 mm (0.01In)

Visually inspect the slider and fork tube bushings. Replace the bush ing if there is axoessiva scoring or scratching, or if the tef lon 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 thereo is any distortion at the points shown.

(1) BUSHING (3) BACK-UP RING

...,,'

'.... ...

(2)

(4)

CHECK POINTS

--++--"" COPPER

SURFACES

15-26

FRONT WHEEL/SUSPENSION

CiiJ\H O NDA

VTSOOC

ASSEMBLY

Before assembly, wash all parts with a high flash point or non -f lammable solvent and wipe them off completely.

(1) FORK CAP BOLT-----

(2) COLLAR

(3) SPR ING

(4) PISTON --- RING

(5) PISTON

Clean all disassembled parts with non-f lammable or high flash point solvent.

Install the bushing onto the inner tube.

Install the piston, rebound spring and oil lock piece into the fork tube.

Apply a locking agent to the bolt threads and under side of the bolt, then tighten the bolt.

TORQUE:15-25 N·m

(1.6-2.5 kg·m, 11-18 ft-lb)

CAUTION

IDo not place the fork slider i n a vise.

15-27

(7)

DUST SEAL

(8)

FOAM WASHER

(9)

PLASTIC WASHER

(10)

SNAP RING

(11)

,.,..-----,OIL SEAL

.... (12)

--------BACK-UP RING

(13)

------SLIDER BUSHING

(14)

!-----_:..:_ FORK SLIDER

(15)

..- ---- SOCKET BOLT

FORK TUBE BUSHING

(17)

OIL LOCK PIECE

Install the snap ring with its radiused edge facing down.

Install the plastic washer, foam washer and dust cover.

Pour in the spaeifi9d amount of ATF. SPECIFIED FLUID: ATF

CAPACITY: 390 ± 2.5 cc

(23.8± 0.1Scu in)

(1)

SNAP RING PLIERS 07914-3230001

,... ;·;c:=4

NOTE

Do not overfill or the suspension will be too stiff.

Insert the fork spring Into the fork to be with the narrow (tight) windings towards the top.

Place the washer and collar on top of the fork spring.

Install and torque the fork tube cap.

TORQUE: 15-30 N·m

(1.5-3.0 kg-m, 11-22 ft-lb)

Install the fork tubes into the :steering stem and fork bridge while rotating them by hand .

NOTE

Be sure that the top of ea<:h tube is f lush with

the top of the fork bridge.

Tighten the fork bridge and steer ing stem pinch bolts on one side.

TORQUE VALUES:

Fork bridge: 9-13N·m

(0.9-1.3 kg-m, 7-9 ft lb)

Steering stem: 45-55 N·m

(4.5-5.5 kirm. 33-40 ft-lb)

Install the fork brace hex bolts loosely.

Tigh ten the fork bridge and steering stem pinch bolt on the other side to the specif ic torque.

NOTE

On not tighten the fork brae<! at this time.

I nstall the front fender and brake caliper bracket. Tighten the caliper bracket mount bolt.

TORQUE: 30-40 N·m

(3.0-4.0 kg·m, 22-29 ft-lb)

I nstall the front wheel (page 15-20).

Tighten the fork brace hex bolts to the specif ied torque.

TORQUE: 18-28 N·m

(1.8-2.8 kg-m, 13-20 ft·l b)

Fill the fork tubes with ai r to 0-40 kPa (0--0.4

kg/cm1, 0-6 psi I,with the motorcyde on its center

stand.

CAUTION

With th t front brake applied, pump the front forks up and down several times. Place the motorcycle on its center stand . Check the air pressu re and adjust if necessary .

STEERING STEM

REMOVAL

Remove the following parts:

- headligh t, headlight case and bracket (page 15 3).

- instrumen ts (page 15-4).

- handlebar (page 15-8).

- fron t wheel ( page 15·14).

- caliper bracket ( page 17-13).

- horn bracket.

- electrical junction box (page 15-4).

R emove the steering stem/bridge n ut. Remove the front forks (page 15-21). Remove the fork bridge.

(11 LOCK NUT WRENCH. 30 K 32 mm, 07716-0020400

EXTENSION BAA 07710020500

Remove the stHring stem adjusting nut, steering stem and steel balls .

Remove the lower cone race and dust seal.

I nstall a dust seal and drive the lower cone race on with the steering stem driver (No. 07946-MBOOOOO or 07946-37 10601 and 07964-MB00200).

(1IPIN SPANNER

(1)

w ::

STEERING STEM DR IVER

BALL RACE R EPLACEME NT

Inspect the top and bottom ball races and replace if worn or damaged.

Remove the upper ball race with the special tool.

NOTE

Remove the sliding guide from the bearing

Ra ce remover.

Reinstall the sliding guide onto the race remover. Remove the lower ball race.

NOTE

Drive the upper ball race into the head pipe with the special tools.

Drive the lower ball race into the head pipe with the special tool.

(1) (Top ball race installation) (5) ( Bottom ball race installation)

FRONT WHEEL/SUSPENSION

INSTALLATION

A pply grease to the top ball race and insta ll 18 ball bearings.

Apply grease to the bottom bal l race and install 19

ball bearings.

Insert the steering stem into the steering head pipe and install the top cone race.

I nstall the bearing adjustment nut and tigh ten it snug against the top cone race. Then , back it off 1/8 turn. Make sure that there is no vertical movement and that the stem rotates freely.

(11 PIN SPANNER 07702-0020000

ADJUSTMENT NUT

I n stall the fork bridge and stem nut.

I nstall the front forks and tighten the stem n u t.

TORQUE:90-120 N·m

19.0-12.0 kg·m, 65-87 ft-lb I

I nstall the removed parts in the reverse order of removal.

( 1) LOCK NUT WRENCH,30 x 32 mm

BRAKE

VT500C

R EAR WHEEL

REMOVAL

Place the motorcycle on its center stand and loosen the axle nut.

Remove the brake torque link bolt and disconnect the torque link.

Remove the brake adjusting nut and the brake rod.

Loosen the axle pinch bolt and remove the rear axle.

(1) AXLE NUT

(3) BRAKE ADJUSTING (41 TORQUE LINK NUT BOLT

Move the wheel to the right to separate it from the final drive gear case and remove the rear wheel.

·. .

.\. ,, ,. -,

DISASSEMBLY

Remove the final driven flaroge mount bolts and lift the driven flange out of the hub.

Remove the wheel bearings and distance collar with the special tool.

Replace the wheel bearings with new ones if they are removed.Inspect the bearings before removing them (page 16-5).

Refer to page 15-16. NOTE

INSPECTION AX LE

Set the axle in V blocks and read the axle runout with a dial indicator. The actual axle runout is 1/2 of the totalindicator reading.

SERVICE LIMIT:0.2 mm (0.01 in)

(1) WHEE L BEARING REMOVER COLLET, 17 mm 07746-0050500

(2) WHEEL BEARING REMOVER EXPANDER 07746-0050100

BRAKE

VT500C

WHEEL BEARINGS

Place the wheel in a truing stand and check the wheel bearing play by rotating the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play.

SERVICE LIMIT:0.03 mm (0.001In)

WHEEL R IM RUNOUT

Check the rim for 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.l() mm (0.08 in) AXIAL RUNOUT: 2.•0 mm (0.08in)

The wheel cannot be serviced and must be replaced if the above limits are exceeded.

BRAKE DRUM 1.0.

Measure the brake drum I.D.

SERVICE LIMIT:161 mm (6.34 in)

BRAKE

VTSO OC

ASSEMBLY

NOTE

Pack all bearing cavities with grease.

Press the distance collar into place from the left side. Drive the left ball bearing i n first, then the right ba ll bea ring.

CAUTION

11) DRI VER

07749-0010000

.--

(2) ATTACHMENT,42 x 47 mm 07746--0010300

l'ILOT. 17 mm 07746-0040400

I nstall the final driven f lange onto the rear wheel and tigh ten the bolts.

TOR QU E: 50-60 N·m

(5.0-6.0 kg-m, 36-43 ft·lb)

INSTALLATI ON

Apply Multipurpose NLGI No. 2 grease (MoS2· additive) to the f1nal driven flange and ring gear engagement splines.

Loosen the final gear case attaching nuts to eue axle installation and to assu re proper driven flange align ment.

Engage the rear wheel with the final drive case, making sure the splines are correctly aligned.

Wedge a f lat screwdriver ti p into the pinch bolt slot.

Insert the rear axle through the swing arm, side collar, brake panel, hub and final drive gear. Turn the axle and check that it rotater freely.

Remove the screwd river from the pinch bol t slot. Tighten the axle n ut to the ified torque.

TOR QUE: 50-80 N·m

(5.0-8.0 kg m, 36-58 ft lb)

(1) FINAL DR IVEN F LANGE

(1) AXLE NUT

REAR WHEEL/SUSPENSION BRAKE

H O NDA

VTSOOC

Tigh ten the axle pinch bolt.

TORQUE: 20-30 N·m

(2.0-3.0 k11-m, 14-22 ft-lb)

Place the brake rod through the brake arm pin and install the brake adjusting nut.

Tighten the brake torque link bolt.

TORQUE: 15-25 N·rn

(1.5-2.5 k11-m, 11-18 ft-lb)

Adf ust the rear brake (page 3·'14) .

REAR BRAKE PANEL

LINING THICK NESS INSPECTION

Measure the rear brake lining t hickness. SERVICE LIMIT:2.0 mm (0.08 in)

Replace the brake shoes if they are thinner than the service limit.

DISASSEMBLY

Remove the rear brake arm.

Remove the cotter pins and brake shoes.

ASSEMBLY

Apply grease to the anchor pins and brake cam.

Install the brake shoes and cotter pins.

(1) AXLE PINCH BOLT (2) R EAR AXLE

(3) BRAKE ADJUSTI NG N UT (4) TORQUE LIN K

BOLT

REAR WHEEL/SUSPENSION BRAKE

H O NDA

VTSOOC

Insta ll the fel t seal and wear ind icator.

I nstall the brake arm, ali gning the punch marks and tighten the brake arm bolt.

TORQUE: 24-30 N·m

(2.4-3.0 kg-m, 17-22 ft-lb)

(1) WEAR INDICATOR

(1) PUNCH MARKS

REAR WHEEL/SUSPENSION BRAK E

SHOCK ABSORB ER

REMOVAL

NOTE

Remove one shock absorber at a time to faci litate removal and installa tion.

Adjust the shock absorber to the softest position.

Remove the shock absorber upper and lower moums and remove the shock absorber.

DISASSEMBLY

H O ND A

VT500C

Replace base and guide of shock compressor, P/N

07959-3290001 with base 07959-MBl0000.

NOTE

(1) SHOCK COMPRESSO

07959-3290001 (2) COLLAR

(3)

CLEVIS PIN

Place the collar, 62486-463-0000 or equivalent in the shack's bottom joint before pu tting the shock in the compressor.

Set the shock in the compressor as shown and com press the spring 30 mm l1 1/4 in) by turning the compressor handle.

CAUTION

Place the upper join t in a 11lse and pull the shock rod out.

Separate the upper join t rotating the lock nut in the

direction shown and remove the compressor.

(4) BASE ADJUSTER NUT (5) BASE 07969-MBt OOOO

(1) UPPER JOINT

REAR WHEEL/SUSPENSION

BRAKE

VTSOOC

SPRING F REE LENGTH

Measure the rear shock absorber spring free length.

SERVICE LIMIT:237 mm ( 9.3 in )

ASSEMBLY

Place the spring adjuster. tlhe spring lower seat, spring upper seat and stopper rubber on the damper.

(21 SP ING UPPER SEAT

(4) SPR ING ADJUSTER

(5) LOCK N UT--®Q,

DP,

131 SPR ING

)..-

LOWER _........,... SEAT

CAUTION

11) UPPER JOINT

Apply a locking agent to the rod threads and install the lock nut.

Attach the shock absorber compressor, screwing in the compressor's base adjuster nut.

Apply a locking agent to the damper rod threads and screw the upper joint on. Hold the upper joint in a vise and tighten the lock nut securely,

NOTE

Check that the lock nut is seated against the rod's bottom thread.

Align the spring seat with the upper jo int while releasing the compressor.

INSTA LLATION

Install the shock absorber onto the frame. Tighten the upper and lower mounts.

TORQUE: 30-40 N·m

(3.0-4.0 kg·m,22-29 ft·lbl

(1) SHOCK COMPRESSOR 07959-3290001

(2) BASE ADJUSTER NUT (3) CLEVIS PIN

SWING A RM

R EMOVAL

Remove the rear wheel (page 16-3) and the final drive gear case (page 14-3).

Remove the rear shock absorbers (page 16-10).

Remove the swing arm pivot caps and loosen the right pivot bolt lock nut with the lock nut wrench.

Remove the right pivot bolt with the 10 mm hex bit.

Remove the left pivot bolt and remove the swing arm.

Remove the boot from the swing arm.

( 1) FINAL GEAR CASE

(1) SWING ARM PIVOT LOCK NUT WRENCH 07908-ME90000

PIVOT BEARING REPLACEMENT

Punch or drill a 13 mm (1/2 in ) hole into each grease retai ner.

Remove the attachment from the special tool, 07936-3710500. Slide the shaft th rough the hole and install a 29 mm (O.D.) washer or equivalent any attachment onto the shaft.

Install the slide hammer and handle remove the race. Repeat for the other side.

NOTE

Replace the bearing Inner and outer races as a set. Replace the grease retainer plate whenever it is removed.