CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES............................................................ 6
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number............................................................... 7
Type label (FE EU, FE AUS) ............................................. 7
Type label (FE USA) ........................................................ 7
Key number (FE EU, FE AUS)........................................... 7
Engine number................................................................ 7
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Jacking up the motorcycle................................................ 9
Removing the motorcycle from the work stand.................... 9
Starting .......................................................................... 9
01/FORK, TRIPLE CLAMP.................................................. 10
Adjusting the compression damping of the fork ................ 10
Adjusting the rebound damping of the fork....................... 10
Adjusting the spring preload of the fork ........................... 10
Bleeding the fork legs .................................................... 11
Cleaning the dust boots of the fork legs ........................... 11
Loosening the fork protection.......................................... 11
Positioning the fork protection ........................................ 12
Removing the fork legs................................................... 12
Installing the fork legs ................................................... 12
Removing the fork protector............................................ 13
Installing the fork protector ............................................ 13
Performing a fork service................................................ 14
Disassembling the fork legs ............................................ 14
Cartridge disassembly .................................................... 17
Disassembling the compression damping fitting ............... 19
Checking the fork legs.................................................... 19
Assembling the compression damping fitting.................... 20
Assembling the cartridge................................................ 21
Assembling the fork legs ................................................ 23
Greasing the steering head bearing.................................. 27
Removing the lower triple clamp ..................................... 27
Installing the lower triple clamp...................................... 28
Checking the play of the steering head bearing................. 29
Adjusting the play of the steering head bearing ................ 29
03/FRAME........................................................................ 30
Removing the engine guard ............................................ 30
Installing the engine guard ............................................. 30
04/SHOCK ABSORBER, SWINGARM................................... 31
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 31
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 31
Adjusting the rebound damping of the shock absorber....... 32
Measuring rear wheel sag unloaded ................................. 32
Checking the static sag of the shock absorber .................. 32
Checking the riding sag of the shock absorber .................. 33
Adjusting the spring preload of the shock absorber ........... 33
Adjusting the riding sag ................................................. 34
Removing the shock absorber ......................................... 34
Installing the shock absorber .......................................... 34
Performing a shock absorber service................................ 35
Removing the spring ...................................................... 35
Disassembling the shock absorber................................... 36
Disassembling the piston rod .......................................... 37
Disassembling the seal ring retainer ................................ 38
Replacing the pilot bushing............................................ 39
Checking the shock absorber .......................................... 39
Disassembling the rebound adjuster ................................ 40
Removing the heim joint ................................................ 41
Installing the heim joint ................................................. 41
Assembling the rebound adjuster .................................... 42
Assembling the seal ring retainer .................................... 43
Assembling the piston rod .............................................. 43
Assembling the shock absorber ....................................... 45
Bleeding and filling the shock absorber ........................... 47
Filling the shock absorber with nitrogen........................... 49
Installing the spring....................................................... 50
Removing the swingarm, with shock absorber and rear
wheel ........................................................................... 51
Installing the swingarm, with shock absorber and rear
wheel ........................................................................... 52
05/EXHAUST .................................................................... 54
Removing the main silencer............................................ 54
Installing the main silencer ............................................ 54
Removing the exhaust system ......................................... 54
Installing the exhaust system.......................................... 55
06/AIR FILTER.................................................................. 57
Removing the air filter ................................................... 57
Installing the air filter .................................................... 57
Cleaning air filter........................................................... 57
07/FUEL TANK, SEAT, TRIM.............................................. 59
Removing the seat ......................................................... 59
Mounting the seat ......................................................... 59
Removing the fuel tank .................................................. 59
Installing the fuel tank................................................... 60
Removing the spoiler ..................................................... 61
Installing the spoiler ...................................................... 61
Checking the fuel pressure ............................................. 62
08/MASK, FENDER, DECAL ............................................... 63
Removing the front fender.............................................. 63
Installing the front fender............................................... 63
Removing the start number plate (FE USA) ...................... 63
Installing the start number plate (FE USA)....................... 64
09/FRONT WHEEL ............................................................ 65
Removing the front wheel............................................... 65
Installing the front wheel................................................ 65
Checking the tire air pressure ......................................... 66
Checking the tire condition............................................. 66
Checking the brake disks................................................ 67
10/REAR WHEEL .............................................................. 68
Removing the rear wheel ................................................ 68
Installing the rear wheel................................................. 68
Checking the chain tension ............................................ 69
Adjusting the chain tension ............................................ 69
Checking the chain wear ................................................ 70
Checking the rear sprocket/engine sprocket for wear ......... 71
Checking for chain dirt accumulation .............................. 71
Cleaning the chain......................................................... 71
Adjusting the chain guide............................................... 72
Checking the spoke tension ............................................ 72
11/WIRING HARNESS, BATTERY ....................................... 73
Disconnecting the negative cable of the battery ................ 73
Connecting the negative cable of the battery .................... 73
Changing the main fuse ................................................. 73
Changing the fuses of individual power consumers............ 74
Removing the battery ..................................................... 75
Installing the battery...................................................... 75
Charging the battery ...................................................... 76
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