Very drfficurt,

suitable for expert DIY <J
or professional ^

Specifications

Note: Models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details.

Front forks

Fork oil type.............................................................................................. 10W fork oil

Fork oil capacity

J and К models....................................................................................... 490 cc

L and N models...................................................................................... 453 cc

R models................................................................................................ 408 cc

Fork oil level*

J and К models....................................................................................... 96 mm

L and N models...................................................................................... 105 mm

R models................................................................................................ 120 mm

Fork spring free length (min) J and К models

Standard............................................................................................. 308.0 mm

Service limit.................................................................................... 302.0 mm

L and N models

Standard......................................................................................... 319.7 mm

Service limit.................................................................................... 313.0 mm

R models

Standard......................................................................................... 295.5 mm

Service limit.................................................................................... 290.0 mm

Fork tube runout limit............................................................................ 0.2 mm

Fork air pressure (J and К models)..................................................... 0 to 5.5 psi

'Oil level is measured from the top of the tube with the fork spring removed and the leg fully compressed.

6«2 Frame, suspension and final drive

Rear suspension

Shock absorber spring free length J and К models

Standard.............................................................................................. 173.7 mm

Service limit......................................................................................... 170.2 mm

L and N models

Standard.............................................................................................. 154.9 mm

Service limit......................................................................................... 152.0 mm

R models

Standard.............................................................................................. 173.5 mm

Service limit.................................................................................... 170.0 mm

Final drive

Chain type

J and К models.................................................................................. RK525SM4 or DID525V8 (106 links, split)

Land R models.................................................................................. RK525SMOZ4 or DID525V8 (102 links, split)

R models............................................................................................ RK525SM5 or DID525V8 (102 links, split))

Joining link pin projection from side plate (unstaked) - R models

RK type chain.................................................................................... 1.2 to 1.4 mm

DID type chain............................................................ 1.15 to 1.55 mm

Joining link staked ends diameter - R models

RK type chain..................................... • • - •.................. 5.50 to 5.80 mm

DID type chain................................................................................ 5.50 to 5.80 mm

Torque settings

Note: Where a specified setting is not given for a particular bolt, the general settings listed at the beginning apply. The dimension given applies to the diameter of the thread, not the head.

5 mm bolt/nut......................................................................................... 5 Nm

6 mm bolt/nut......................................................................................... 10 Nm

8 mm bolt/nut.......................................................................................... 22 Nm

10 mm bolt/nut........................................................................................ 35 Nm

12 mm bolt/nut....................................................................................... 55 Nm

6 mm flange bolt with 8 mm head....................................................... 9 Nm

6 mm flange bolt/nut with 10 mm head............................................... 12 Nm

8 mm flange bolt/nut........................................................................... 27 Nm

10 mm flange bolt/nut......................................................................... 40 Nm

Rider's footrest bracket bolts................................................................ 27 Nm

Rider's footrest holder bolt................................................................... 37 Nm

Top yoke fork clamp bolts

J and К models.................................................................................. 11 Nm

L, N and R models........................................................................... 23 Nm

Handlebar clamp bolts.......................................................................... 27 Nm

Front brake master cylinder clamp bolts............................................ 12 Nm

Bottom yoke fork clamp bolts........................................................... 35 Nm

Fork top bolt.......................................................................................... 23 Nm

Damper rod Allen bolt........................................................................... 20 Nm

Steering stem nut................................................................................... 105 Nm

Steering head bearing adjuster nut........................................................ 22 Nm

Shock absorber mounting nuts/belts....................................................... 55 Nm

Suspension linkage mounting nuts/bolts............................................... 55 Nm

Swingarm adjuster bolt............................................................................. 15 Nm

Adjuster bolt locknut (special tool required - see text).......................... 65 Nm

Pivot bolt nut

J and К models...................................................................................... 90 Nm

L, N and R models............................................................................... 95 Nm

Front sprocket bolt.................................................................................... 55 Nm

Rear sprocket bolts (J and К models).................................................. 75 Nm

Rear sprocket nuts (L, N and R models)................................................. 50 Nm

Frame, suspension and final drive 6*3

1 General information

All models use a twin spar box-section aluminium frame which uses the engine as a stressed member.

Front suspension is by a pair of oil-damped telescopic forks. On J and К models, the forks have a conventional damper system and are air-assisted. On L and N models, the forks have a conventional damper system and are adjustable for spring pre-load. On R models, the forks have a cartridge damper and are adjustable for spring pre-load and rebound damping.

At the rear, an alloy swlngarm acts on a single shock absorber via a three-way linkage. The shock absorber Is adjustable for spring pre-load on all models, and also for rebound damping on L, N and R models.

The drive to the rear wheel is by chain.

Models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details.

2 Frame - inspection and repair

1 The frame should not reqjire attention unless accident damage has occurred. In most cases, frame renewal is the only satisfactory remedy for such damage. A few frame specialists have the jigs and other equipment necessary for straightening the frame to the required standard of accuracy, but even then there is no simple way of assessing to what extent the frame may nave been over stressed.

2 After the machine has accumulated a lot of miles, the frame should be exsmined closely for signs of cracking or splitting at the welded joints. Loose engine mount bolts can cause

ovallng or fracturing of the mounting tabs. Minor damage can often be repaired by specialist welding, depending on the extent and nature of the damage. 3 Remember that a frame which is out of alignment will cause handling problems. If misalignment is suspected as the result of an accident, it will be necessary to strip the machine completely so the frame can be thoroughly checked.

3 Footrests, brake pedal and ||>
gearchange lever - removal |к
and installation ^

Rider's footrests

Removal

1 Remove the split pin and washer from the
bottom of the footrest pivot pin, then
withdraw the pivot pin and remove the
footrest, noting the fitting of the return spring
(see illustration).

Installation

2 Installation Is the reverse of removal. Use a
new split pin and bend its ends securely.

Passenger footrests

Removal

3 Remove the seat cowling (see Chapter 8).

4 Unscrew the two bolts securing the bracket to the frame and remove the footrest assembly, noting how it fits (see illustration).

Installation

5 Installation is the reverse of removal. Prior
to installation, clean the assembly and remove
all the old grease, then apply some new
grease to the release mechanism and pivot
points.

Brake pedal

Removal

6 Unhook the brake pedal return spring and the brake light switch spring from the pin on the pedal (see illustration).

7 Remove the split pin and washer from the

■hL

3.1 Remove the split pin and washer (A)

and withdraw the pivot pin. Note how the

spring ends (B) locate

clevis pin securing the brake pedal to the master cylinder pushrod (see illustration). Remove the clevis pin and separate the pedal from the pushrod.

8 The pedal pivots on the footrest holder. Remove the bolt on the Inside of the footrest bracket and remove the footrest and its holder (see illustration 3.7). Remove the wave washer and slide the pedal off the holder. Installation

9 Installation is the reverse of removal, noting the following:

a) Apply molybdenum disulphide grease to the brake pedal pivot

b) Align the flat on the footrest holder with that in the bracket. Do not forget the wave washer.

c) Apply a suitable non-permanent thread locking compound to the brake pedal/footrest holder bolt and tighten it to the torque setting specified at the beginning of the Chapter.

d) Use a new split pin on the clevis pin securing the brake pedal to the master cylinder pushrod and bend the split pin ends securely.

e) Check the operation of the rear brake light switch (see Chapter 1).

Gearchange lever

Removal

10 Slacken the gearchange lever linkage rod locknuts, then unscrew the rod and separate

3.4 Unscrew the two bolts (arrowed) and remove the assembly

3.6 Unhook the springs (arrowed) from the pin

3.7 Remove the split pin (A) and withdraw

the clevis pin (B). Brake pedal/footrest

holder bolt (C)

6*4 Frame, suspension and final drive

Дата добавления: 2015-10-29