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36 views17 pages15-Front Wheel-Suspension-Steering Part 2
Ho da VT 800
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0% found this document useful (0 votes)
36 views17 pages15-Front Wheel-Suspension-Steering Part 2
Ho da VT 800
Uploaded by
Jose RamirezCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 17
FRONT WHEEL/SUSPENSION/STEERING
Remove the dust seal and spoadometer gearbox from the
wheel
Mount the wheel, tire and brake dise assembly in an inspection
stand,
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk.
Do this two or three times to verify the heaviest area, If the
wheal is balanced, it will not stop consistently in the same po-
sition,
To balance the wheel, install whool weights on the highest
side of the rim, the side opposite the chalk marks. Add just
enough weight so the wheel will no longer stop in the same po-
sition when it's spun.
Do not add more than 60 grams to the front wheel.
‘Wheel bearing
‘Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the hub,
Remove and discard the bearings if the races do not turn
smoothly, quietly, or if they fit loosely in the hub.
NOTE
+ Replace hub bearings in pairs
BEARING REPLACEMENT
Install the bearing remover head into the bearing.
From the opposite side install the bearing remover shaft and
drive the bearing out of the wheel
NOTE
+ If the bearings are removed, they must be replaced with
Toots:
Bearing remover shaft 077460050100
Bearing remover head, 15 mm 077460050400
(oF equivalent commercially
avaitable in U.S.A.
(INSPECTION
STAND
CLBALANCE WEIGHT]
NG.) seannc hander Sane
15-10 FRONT WHEEL/SUSPENSION/STEERING
Remvoe the distance collar from the whee! hub. pee STANCE COLA
Remove the other bearing from the hub using the same tools.
Remove the brake dise mounting bolts and the brake dise.
Drive @ new left bearing into the wheel until it is fully seated
first.
077490010000
Attachment, 42 47mm 077480010300
Pilot, 15 mm_ 077480040300
NOTE
+ Do not sllow the bearings to tlt while driving ther in
+ Never install an old bearing, once a bearing is removed, it
must be replaced with a new one.
—
|
nana (2) ATTACHMENT/PILOT.
Install the distance collar into the whee! hub,
Drive # new right bearing into the wheel until itis Tully seated,
osc
D2 WHEEL HUB
15-11 FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
om
+ Do not get grease on the brake disc or stopping power will be
reduced.
60 Nem
(6.0 ko-m, 43 ft-lb]
>
40 Nem (4.0 kg-m, 29 felb)
Install the brake disc onto the wheel hub with minimum thick OT BRAKE OSCE ST
ness marking (MIN TH 2.0 mm facing out. Peers Tae
Clean and apply locking agent to the mounting bolt threads, =>
Tighton the bolts to specified torque.
NoTE
+ Tigiton the bolts in a crisscross pattern in 2 or 3 steps.
TORQUE: 40 Nem (4.0 kg-m, 29 feb)
REE
+ Do not get grease on the brake dise or stopping power will be
reduced.
‘Coat the speedometer gear retainer with clean grease and in
stall the retainer into the wheel hub, aligning the tangs with
the slots in the hub.
Apply clean grease to the oil seal lips and install the oil seal
‘over the gear retainer. FRONT WHEEL/SUSPENSION/STEERING
Fill the speedometer gear box with clean grease and install the
plain washer and drive gear.
Install the spoodomater gear box into the whoo! hub.
Apply clean grease to the ol seal lip and install the seal into the
wheel.
Install the side collar.
Insert the axle from the left side, then install and tighten the:
axle nut
TORQUE: 60 N-m (6.0 kg-m, 43 ft-lb)
INSTALLATION
Position the wheel between the fork legs.
Lower the frame so that the fork legs rest on the top of the axle
and the brake disc is positioned between the pads.
CAUTION
+ Use care nol to damage the pads when installing the wheel
Position the tang on the speedometer gear box against the
bback of the lug on the left fork.
15-13 FRONT WHEEL/SUSPENSION/STEERING
Loosely install the axle holders with the arrow mark facing for-
ward,
Tighten the axle holder nuts, starting with the forward nut,
TORQUE: 30 Nem (3.0 kg-m, 22 ftdb)
Connect the sepeadiometer cable to the gear box and tighten
the set screw securely.
FORK
REMOVAL
Romove the following:
front wheel (page 15-71
brake caliper (page 17-9)
mounting bolts and fender.
(2) MOUNTING BOLTS
Loosen the top bridge pinch bolt
If the fork tubes will be disassembled, loosen the fork tube
‘caps but do nat remove them yet,
‘CAUTION
+ Do not use a orescent wrench to loosen the fork tube caps, it
‘may damage them
Loosen the fork bottom pinch bolts and remove the fork tubes
from the top bridge and steering stem.
(2) STEERING STEM
15-14 FRONT WHEEL/SUSPENSION/STEERING
—.h9aoa9oa ane re L/SUSPENSION/STEERING
DISASSEMBLY
Romove the fork tube cap.
+ The cap és under spring pressure. Use care when removing it
and wear eve and face protecto
Hold the fork slider in a vise with soft jaws or use a shop towel (1) FORK SLIDER,
Remove the socket bolt with a hex wrench.
NoTE
+ Temporarily install the spring and fork bok if aificulty is en-
countered in removing the bolt
(2) SOCKET BOLT
Remove the dust seal with oscroweriver (2) SCREWDRIVER (1) DusT SEAL
eAUTION i
+ Bo no serach The fork tube sng |
Remove the stopper ring (STOPPER RING jj
CAUTION
+ Do not seruich the fork tube sliding surface,
(2) SCREWORIVER, FRONT WHEEL/SUSPENSION/STEERING
Pull the fork tube out until resistance from the slider bushing Is (1) FORK SLIDER
felt. Then move it in and out, tapping the bushing lightly until
the fork tube separates from the slider. The slider bushing will
bo forced out by the fork tube bushing.
(2) FORK TUBE
Romove the oil lock piece and stopper ring from the piston, (1) STOPPER RING (3) PISTON
Romove the piston and rebound spring from the fark tube.
(2) O1L Lock Plece
Remove the oil seal, back-up ring and slider bushing from the (1) OL SEAL 2) BACK-UP RING
fork tube. |
NoTE
+ Do not remove the fork tube bushing unless itis necessary
to replace it with a new one, See bushing inspection, page
15-17.
(3) SLIDER BUSHING (4) FORK TUBE BUSHING.
INSPECTION
Fork spring
Measure the fork spring free length.
SERVICE LIMIT: 417.7 mm (16.44 in}
UAKAAARANAAA VY YY 0
Replace the spring if itis shorter than the service limi
(1) FORK SPRING
15-16 Fork tube/slideripiston
Check the fork tube, fork slider and piston for score marks and
‘oxcossive or abnormal wear,
Replace any components which are worn or damaged.
Check the fork piston ring for weer 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 run-
our.
SERVICE LIMIT: 0.20 mm (0.008 in}
Bushings
Visuelly inspect the slider and fork tube bushings,
Replace the bushings if there is excessive scoring or scratch:
ing, orif the teflon is worn so that the copper surface appears
fon mora than 3/4 of the entire surface.
Check the back-up ring; replace it if there is any distortion at
the points shown,
ASSEMBLY
Before assembly, wash all parts with a high flash point or non-
flammable solvent and wige them off completely,
FRONT WHEEL/SUSPENSION/STEERING
(3) PISTON RING
(2) PISTON
(1) FORK SLIDER
TUBE
(1) Fork TUBE
[11 BUSHING
‘TEFLON
SURFACE
(4) COPPER
SURFACES
(2) BACK-UP RING
xe
(3) CHECK POINTS
15-17 FRONT WHEEL/SUSPENSION/STEERING
(0) Fon TUBE CaP (2) 0UST seat
pos, Ta) STOPPER ANG
34 t o1 sean
(18) FORK TUBE SPACER SZ) wack ve rin
y S+— (6) SUDER BUSHING
117} SPRING SEAT- = {7
/ / (7) super
(16) FORK SPRING —», //
/
[iL ter ron Tuee
[pe
(15) PISTON RING —= / /
A EJ sorrore rues ft
(14) PISTON cea BUSHING £
vw
3 (11) STOPPER RING ge” '8! SOCKET BoLT
oe
(13) REBOUND SPRING
(12) OL Lock PIECE
(1) STOPPER RING
Assemble the rebound spring onto the piston.
Insert the piston assembly into the fork tubs.
Install new stopper ring onto the piston groove.
Place the oil lock piece on the end of the piston and insert the
fork tube assembly into the slider.
(3) PISTON ASSEMBLY
11 FORK SLIDER
Place the fork slider in a vise with soft jaws or use @ shop towel th
‘to avoid demaging the slider.
Clean and apply a locking agent to the socket bolt threads and
screw the bolt into the piston,
Tighten the bolt with @ 6 mm hex wrench tte
NOTE
+ Temporarily install the fork spring and fork tube cap to
tighten the socket bolt.
TORQUE: 20 Nem (2.0 kg-m, 14 feb}
A
(2) OL LOCK PIECE
(2) SOCKET BOLT
15-18 Place the slider bushing over the fork tube and rest it on the
slider.
Drive the bushing into place with the seal driver.
Coat a new ol seal with ATF and instal it with the seal mark:
ings facing up. Drive the seal in with the seal driver.
TooLs:
Fork seal driver 079474630100
Install the stopper ring securely into the groove in the fork
siidor firmly.
‘CAUTION
+ Do not scratch the fork tube sliding surface.
Install the new dust seal onto the fork slider.
Compress the fork tube and pour in the recommended fork oil
to the specified level.
RECOMMENDED FORK OIL: ATF or EQUIVALENT
‘SPECIFIED LEVEL: 134 mm (6.3 in)
CAPACITY: 445 ce [15.1 US 07]
Install the fork spring wvith gently into the fork tube. Install the
spring seat and spacer into the fork tube,
NOTE
+ Note the spring direction; the tapered end must face toward
the bottom:
Loosoly install the fork tube cap with a new O-ring.
CAUTION
+ Do not damage the fork tube sliding suzface.
FRONT WHEEL/SUSPENSION/STEERING
(1) FORK SEAL DRIVER,
.
(1) STOPPER RING
i
aa
a eee
- | ae
|) 11) sPecirteo|
LeveL
15-19 FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Install the fork tube and align the top end with the upper sur-
face of the top bridge as shown.
Apply oll to the lower pinch bott thread and tighten it.
TORQUE: 50 Nem (5.0 kgm, $6 ft)
Screw in the upper pinch bolt but do not tighten it.
Tighten the fork tube cap fist.
TORQUE: 23 Nem (2.3 kg-m, 17 ft)
Then tighten the top pinch bolt to avoid damage the fork cap
threads,
TORQUE: 11 Nem (1.1 kg-m, 8 ft)
Install the following
tender and brake caliper (page 17-11)
“front whee! (page 15-12)
With the front brake applied, compress the fork up and down
several timos to check for proper fork and wheel assembly,
STEERING STEM
REMOVAL
Remove the following:
—headlight and headlight case Ipage 21-8)
instruments (page 21-6)
—handlebar (page 15-3)
front wheel {page 15-7)
12) HANDLEBAR
15-20 FRONT WHEEL/SUSPENSION/STEERING
Remove the steering stem cover by romoving the two caps’ [TT CAPSTBOLTS
bots
Remove the steering stem nut
Toots:
Lock nut wrench, 30 x 32 mm 077160020400
or oquivalonts commer
available in U.S.A.
Extension bar 0716 -0020500
Romove the fork tube and top bridge.
Remove the headlight case bracket mounting bolts and the
bracket from the steering stem
(2) MOUNTING BOLTS]
| Straighten the Jock washer tabs and remove the lock nut and (1) LOCK NUT.
lock washer:
(2) LOCK WASHER
15-21 FRONT WHEEL/SUSPENSION/STEERING
Remove the bearing adjustment nut.
Tool:
Steering stom socket 07916~3710100
Remove the dust seal, upper bearing inner race and bearing
then remove the steering stem,
Remove the grease ratainer from the stem.
Check the bearings, inner and outer races for wear or damage
and replace if necessary,
BEARING RACE REPLACEMENT
NoTE
+ Always replace the bearing and races as a set
Remove the upper bearing outer race with the A side of the ball
TOOL:
Ball race remover
(07953-MJ10000 or
07953—MJO000A
(S.A. only)
Remove the lower bearing outer race with the ball race remov:
fer and attachment,
TooLs:
Ball race remover
Ball race remover attachement
07953—4250002
07946~3710500
Install the stem nut onto the stem to pravent the threads from
being damaged when removing the lower bearing inner race
from the stem.
Remove the lower bearing inner race with @ chisel or equiva-
lent tool, being careful not to damage the stem.
Remove the dust seal
(1) STEERING STEM SOCKET \
ieee
_\,
(1) STEERING STEM
(2) UPPER BEARING INNER RACE
ae
[2) ATTACHMENT.
[1] DUST SEAL (3) STEM NUT.
(2) LOWER BEARING
INNER RACE
15-22 FRONT WHEEL/SUSPENSION/STEERING
NOTE
If the motorcycle has been involved in accident, examine
the area around the steering head cracks,
50 Nem (6.0 kgm, 96 Fb)
J — 11) cock nur
[2] LOCK WASHER