TABLE OF CONTENTS
2
3
4
5
6
2
MEANS OF REPRESENTATION ........................ 7
1.1
1.2
Symbols used ....................................... 7
Formats used ........................................ 7
SAFETY ADVICE ............................................... 8
2.1
Repair Manual ....................................... 8
2.2
Safety advice ........................................ 8
2.3
Degrees of risk and symbols ................ 8
2.4
Work rules ............................................. 8
IMPORTANT NOTES ......................................... 9
3.1
Manufacturer and implied warranty ...... 9
3.2
Operating and auxiliary substances ..... 9
3.3
Spare parts, accessories ...................... 9
3.4
Figures .................................................. 9
SERIAL NUMBERS .......................................... 10
4.1
4.2
4.3
4.4
4.5
4.6
Chassis number .................................. 10
Type label (FE EU/ AU) .. . .. . .. . .. . .. . .. . . .. . .. 1 0
Key number (FE EU/AU) ...................... 10
Engine number .................................... 10
Fork part number ................................ 11
Shock absorber article number .......... 11
MOTORCYCLE ................................................ 12
5.1
Raising the motorcycle with a lift
stand ................................................... 12
5.2
Removing the motorcycle from the
lift stand .............................................. 12
5.3
Starting ............................................... 12
5.4
Starting the motorcycle for a check .... 13
FORK, TRIPLE CLAMP ................................... 14
6.1
Adjusting the compression damping
of the fork ............................................ 14
6.2
Adjusting the rebound damping of
the fork ................................................ 14
6.3
Bleeding the fork legs ......................... 15
6.4
Cleaning the dust boots of the fork
legs ..................................................... 15
6.5
Removing the fork legs ....................... 16
6.6
Installing the fork legs ......................... 16
6. 7
Removing the fork protector ............... 17
6.8
Installing the fork protector ................. 17
6.9
Performing a fork service .................... 18
6.10
Disassembling the fork legs ................ 18
6.11
Removing the spring ........................... 20
6.12
Disassembling the cartridge ............... 21
6.13
Disassembling the piston rod ............. 22
6.14
Disassembling the hydrostop unit ...... 24
6.15
Disassembling the seal ring
retainer ................................................ 24
7
8
9
6.16
Checking the fork legs ........................ 25
6.17
Assembling the seal ring retainer ........ 26
6.18
Assembling the hydrostop unit ........... 26
6.19
Assembling the piston rod .................. 27
6.20
Assembling the cartridge .................... 29
6.21
Assembling the fork legs .................... 30
6.22
Lubricating the steering head
bearing ................................................ 35
6.23
Removing the lower triple clamp ........ 35
6.24
Installing the lower triple clamp .......... 36
6.25
Checking the play of the steering
head bearing ....................................... 38
6.26
Adjusting the steering head bearing
play ..................................................... 38
6.27
Changing the steering head
bearing ................................................ 39
HANDLEBAR, CONTROLS .............................. 41
7.1
7.2
7.3
7.4
7.5
7.6
Handlebar position .............................. 41
Adjusting the handlebar position ........ 41
Adjusting the basic position of the
clutch lever .......................................... 42
Checking the routing of the throttle
cable ................................................... 42
Checking the play in the throttle
cable ................................................... 43
Adjusting the play in the throttle
cable ................................................... 43
FRAME ............................................................ 45
8.1
8.2
8.3
Removing the engine guard ................ 45
Installing the engine guard .................. 45
Checking the frame ............................. 45
SHOCK ABSORBER, SWINGARM .................. 46
9.1
Adjusting the high-speed
compression damping of the shock
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
absorber.............................................. 46
Adjusting the low-speed
compression damping of the shock
absorber.............................................. 46
Adjusting the rebound damping of
the shock absorber ............................. 4 7
Measuring rear wheel sag
unloaded ............................................. 48
Checking the static sag of the
shock absorber ................................... 48
Checking the riding sag of the
shock absorber ................................... 49
Adjusting the spring preload of the
shock absorber ................................... 49
Adjusting the riding sag ...................... 50
Removing the shock absorber ............ 51
