CHASSIS 5-1
5
CHASSIS
CONTENTS
EXTERIOR PARTS ...................................................................................................................................... 5- 2
CONSTRUCTION .................................................................................................................................. 5- 2
REMOVAL ............................................................................................................................................. 5- 3
REMOUNTING ...................................................................................................................................... 5- 6
FRONT WHEEL ............................................................................................................................................ 5- 7
CONSTRUCTION .................................................................................................................................. 5- 7
REMOVAL ............................................................................................................................................. 5- 9
INSPECTION AND DISASSEMBLY ..................................................................................................... 5- 9
REASSEMBLY ...................................................................................................................................... 5-10
REMOUNTING ...................................................................................................................................... 5-11
FRONT FORK .............................................................................................................................................. 5-12
CONSTRUCTION .................................................................................................................................. 5-12
REMOVAL AND DISASSEMBLY ......................................................................................................... 5-13
INSPECTION ........................................................................................................................................ 5-16
REASSEMBLY AND REMOUNTING ................................................................................................... 5-16
STEERING ................................................................................................................................................... 5-22
CONSTRUCTION .................................................................................................................................. 5-22
REMOVAL AND DISASSEMBLY ......................................................................................................... 5-22
INSPECTION AND DISASSEMBLY ..................................................................................................... 5-24
REASSEMBLY AND REMOUNTING ................................................................................................... 5-24
STEERING TENSION ADJUSTMENT ................................................................................................. 5-27
REAR WHEEL .............................................................................................................................................. 5-28
CONSTRUCTION .................................................................................................................................. 5-28
REMOVAL ............................................................................................................................................. 5-30
INSPECTION AND DISASSEMBLY ..................................................................................................... 5-31
REASSEMBLY ...................................................................................................................................... 5-32
REMOUNTING ...................................................................................................................................... 5-33
REAR SUSPENSION ................................................................................................................................... 5-34
CONSTRUCTION .................................................................................................................................. 5-34
REMOVAL ............................................................................................................................................. 5-36
INSPECTION AND DISASSEMBLY ..................................................................................................... 5-37
REASSEMBLY ...................................................................................................................................... 5-39
REAR SHOCK ABSORBER DISPOSAL ............................................................................................. 5-40
REMOUNTING ...................................................................................................................................... 5-41
FINAL INSPECTION AND ADJUSTMENT .......................................................................................... 5-42
SUSPENSION SETTING ...................................................................................................................... 5-42
FRONT BRAKE ............................................................................................................................................ 5-43
CONSTRUCTION .................................................................................................................................. 5-43
BRAKE PAD REPLACEMENT ............................................................................................................. 5-44
BRAKE FLUID REPLACEMENT .......................................................................................................... 5-44
BRAKE CALIPER REMOVAL AND DISASSEMBLY .......................................................................... 5-45
BRAKE CALIPER INSPECTION ......................................................................................................... 5-46
BRAKE CALIPER REASSEMBLY AND REMOUNTING .................................................................... 5-46
BRAKE DISC INSPECTION ................................................................................................................. 5-48
BRAKE DISC REMOVAL AND REMOUNTING ................................................................................... 5-48
MASTER CYLINDER REMOVAL AND DISASSEMBLY ..................................................................... 5-49
MASTER CYLINDER INSPECTION .................................................................................................... 5-50
MASTER CYLINDER REASSEMBLY AND REMOUNTING ............................................................... 5-51
REAR BRAKE .............................................................................................................................................. 5-53
CONSTRUCTION .................................................................................................................................. 5-53
BRAKE PAD REPLACEMENT ............................................................................................................. 5-54
BRAKE FLUID REPLACEMENT .......................................................................................................... 5-54
BRAKE CALIPER REMOVAL AND DISASSEMBLY .......................................................................... 5-55
BRAKE CALIPER INSPECTION ......................................................................................................... 5-56
BRAKE CALIPER REASSEMBLY AND REMOUNTING .................................................................... 5-56
MASTER CYLINDER REMOVAL AND DISASSEMBLY ..................................................................... 5-57
MASTER CYLINDER INSPECTION .................................................................................................... 5-58
MASTER CYLINDER REASSEMBLY AND REMOUNTING ............................................................... 5-59
CLUTCH MASTER CYLINDER ................................................................................................................... 5-60
CONSTRUCTION .................................................................................................................................. 5-60
REMOVAL ............................................................................................................................................. 5-60
DISASSEMBLY AND REASSEMBLY .................................................................................................. 5-60
TIRES AND WHEELS .................................................................................................................................. 5-61
TIRE REMOVAL .................................................................................................................................... 5-61
INSPECTION ........................................................................................................................................ 5-61
TIRE INSTALLATION ........................................................................................................................... 5-62
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