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TABLE OF CONTENTS
MEANS OF REPRESENTATION ........................................ 6
1.1
Symbols used ....................................................... 6
1 .2
Formats used .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . 6
2
SAFETY ADVICE ............................................................... 7
2.1
Repair Manual ....................................................... 7
2.2
Safety advice ........................................................ 7
2.3
Degrees of risk and symbols ................................ 7
2.4
Work rules ............................................................. 7
3
IMPORTANT NOTES ......................................................... 8
3.1
Manufacturer and implied warranty ...................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories ...................................... 8
3.4
Figures .................................................................. 8
4
SERIAL NUMBERS ............................................................ 9
4.1
Chassis number .................................................... 9
4.2
Type label. ............................................................. 9
4.3
Engine number ...................................................... 9
4.4
Fork part number .................................................. 9
Shock absorber article number ............................ 9
4.5
5
MOTORCYCLE ................................................................ 10
5.1
Raising the motorcycle with a lift stand .............. 10
5.2
5.3
Starting ............................................................... 10
5.4
Starting the motorcycle to make checks ............ 11
FORK, TRIPLE CLAMP ................................................... 12
6
6.1
fork ...................................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs ......................................... 12
6.4
Cleaning the dust boots of the fork legs ............. 13
Removing the fork legs ....................................... 13
6.5
6.6
Installing the fork legs ......................................... 14
6.7
Removing the fork protector ............................... 14
6.8
Installing the fork protector ................................. 15
6.9
Performing a fork service .................................... 15
6.10
Disassembling the fork legs ................................ 15
6.11
Removing the spring ........................................... 17
6.12
Disassembling the cartridge ............................... 18
6.13
Disassembling the cartridge ............................... 19
6.14
Disassembling the piston rod ............................. 20
6.15
Disassembling the hydrostop unit ...................... 21
6.16
Disassembling the seal ring retainer ................... 22
6.17
Checking the fork legs........................................ 22
6.18
Assembling the seal ring retainer ........................ 23
6.19
Assembling the hydrostop unit ........................... 24
6.20
Assembling the piston rod .................................. 25
6.21
Assembling the cartridge .................................... 26
6.22
Assembling the fork legs .................................... 27
6.23
Greasing the steering head bearing .................... 31
6.24
Removing the lower triple clamp ........................ 31
6.25
Installing the lower triple clamp .......................... 32
6.26
Checking the steering head bearing play ........... 33
6.27
Changing the steering head bearing ................... 34
6.28
bearing ................................................................ 35
7
HANDLEBAR, CONTROLS .............................................. 36
7.1
Handlebar position .............................................. 36
7.2
Adjusting the handlebar position ........................ 36
7.3
lever .................................................................... 36
7.4
Checking the throttle cable routing .................... 37
7.5
Checking the play in the throttle cable ............... 37
7.6
Adjusting the play in the throttle cable ............... 38
8
FRAME ............................................................................ 39
8.1
Checking the frame ............................................. 39
9
SHOCK ABSORBER, SWINGARM .................................. 40
9.1
damping of the shock absorber. ......................... 40
9.2
damping of the shock absorber. ......................... 40
9.3
absorber .............................................................. 41
9.4
Measuring rear wheel sag unloaded ................... 41
9.5
absorber .............................................................. 41
9.6
absorber .............................................................. 42
9.7
absorber .............................................................. 42
9.8
Adjusting the riding sag ...................................... 43
9.9
Removing the shock absorber ............................ 43
9.10
Installing the shock absorber .............................. 44
9.11
Checking the shock absorber linkage ................ 45
9.12
Servicing the shock absorber ............................. 4 7
9.13
Removing the spring ........................................... 48
9.14
Disassembling the damper ................................. 48
9.15
Disassembling the piston rod ............................. 49
9.16
Disassembling the seal ring retainer ................... 50
9.17
Changing the pilot bushing ................................. 51
9.18
Checking the damper ......................................... 52
9.19
Removing the heim joint ..................................... 52
9.20
Installing the heim joint ....................................... 53
9.21
Assembling the seal ring retainer ........................ 54
9.22
Assembling the piston rod .................................. 55
9.23
Assembling the damper ...................................... 56
9.24
Bleeding and filling the damper .......................... 58
9.25
Filling the damper with nitrogen ......................... 60
9.26
Installing the spring ............................................. 61
9.27
Checking the swingarm ...................................... 62
9.28
Removing the swingarm ..................................... 62
9.29
Installing the swingarm ....................................... 63
9.30
Changing the swingarm bearing ......................... 64
1 0
EXHAUST . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. 67
10.1
Removing the manifold ....................................... 67
10.2
Installing the manifold ......................................... 67
10.3
Removing the main silencer ................................ 68
10.4
Installing the main silencer .................................. 68
10.5
main silencer ....................................................... 68
11
AIR FILTER ...................................................................... 70
11.1
Removing the air filter box lid ............................. 70
11.2
Installing the air filter box lid ............................... 70
11.3
Removing the air filter ......................................... 70
11.4
Installing the air filter ........................................... 70
Cleaning the air filter and air filter box ................ 71
11.5
11.6
Sealing the air filter box ...................................... 71
12
FUEL TANK, SEAT, TRIM ................................................ 72
12.1
Opening the filler cap .......................................... 72
2
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