7
CHASSIS 7-1
CONTENTS
CHASSIS
EXTERIOR PARTS .................................................................................................................... 7- 2
CONSTRUCTION ............................................................................................................. 7- 2
REMOVAL ........................................................................................................................7- 4
REMOUNTING .................................................................................................................. 7-10
FRONT AND REAR WHEELS .................................................................................................. 7-11
CONSTRUCTION ............................................................................................................. 7-11
REMOVAL ........................................................................................................................7-11
REMOUNTING .................................................................................................................. 7-11
TIRES ......................................................................................................................................... 7-12
TIRE REPLACEMENT ...................................................................................................... 7-12
FRONT DRIVE SHAFT ..............................................................................................................7-14
CONSTRUCTION ............................................................................................................. 7-14
REMOVAL ........................................................................................................................7-14
INSPECTION AND DISASSEMBLY ................................................................................ 7-14
REMOUNTING .................................................................................................................. 7-18
FRONT BRAKE ......................................................................................................................... 7-19
CONSTRUCTION ............................................................................................................. 7-19
BRAKE PAD REPLACEMENT ........................................................................................ 7-20
BRAKE FLUID REPLACEMENT ..................................................................................... 7-21
BRAKE CALIPER REMOVAL AND DISASSEMBLY ...................................................... 7-21
BRAKE CALIPER INSPECTION ...................................................................................... 7-23
BRAKE CALIPER REASSEMBLY AND REMOUNTING ................................................ 7-24
BRAKE DISC REMOVAL AND DISASSEMBLY ............................................................. 7-26
BRAKE DISC INSPECTION ............................................................................................. 7-27
BRAKE DISC REASSEMBLY AND REMOUNTING ....................................................... 7-27
MASTER CYLINDER REMOVAL AND DISASSEMBLY ................................................. 7-28
MASTER CYLINDER INSPECTION ................................................................................. 7-30
MASTER CYLINDER REASSEMBLY AND REMOUNTING ........................................... 7-30
FRONT SUSPENSION .............................................................................................................. 7-32
CONSTRUCTION ............................................................................................................. 7-32
REMOVAL AND DISASSEMBLY .................................................................................... 7-33
INSPECTION .................................................................................................................... 7-35
REASSEMBLY AND REMOUNTING ............................................................................... 7-38
STEERING ................................................................................................................................. 7-41
CONSTRUCTION ............................................................................................................. 7-41
REMOVAL AND DISASSEMBLY .................................................................................... 7-42
INSPECTION .................................................................................................................... 7-44
REASSEMBLY AND REMOUNTING ............................................................................... 7-46
TOE-IN ADJUSTMENT .................................................................................................... 7-48
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND
STEERING REASSEMBLING INFORMATION ........................................................................ 7-49
REAR BRAKE ........................................................................................................................... 7-50
CONSTRUCTION ............................................................................................................. 7-50
BRAKE PAD REPLACEMENT ........................................................................................ 7-51
BRAKE FLUID REPLACEMENT ..................................................................................... 7-52
BRAKE CALIPER REMOVAL AND DISASSEMBLY ...................................................... 7-52
BRAKE CALIPER INSPECTION ...................................................................................... 7-54
BRAKE CALIPER REASSEMBLY AND REMOUNTING ................................................ 7-55
BRAKE DISC REMOVAL AND DISASSEMBLY ............................................................. 7-57
BRAKE DISC INSPECTION ............................................................................................. 7-57
BRAKE DISC REASSEMBLY AND REMOUNTING ....................................................... 7-58
MASTER CYLINDER REMOVAL AND DISASSEMBLY ................................................. 7-59
MASTER CYLINDER INSPECTION ................................................................................. 7-60
MASTER CYLINDER REASSEMBLY AND REMOUNTING ........................................... 7-61
REAR SUSPENSION ................................................................................................................7-63
CONSTRUCTION ............................................................................................................. 7-63
REMOVAL ........................................................................................................................7-64
INSPECTION AND DISASSEMBLY ................................................................................ 7-65
REASSEMBLY AND REMOUNTING ............................................................................... 7-66
REAR AXLE .............................................................................................................................. 7-68
CONSTRUCTION ............................................................................................................. 7-68
REMOVAL ........................................................................................................................7-69
INSPECTION AND DISASSEMBLY ................................................................................ 7-69
REASSEMBLY AND REMOUNTING ............................................................................... 7-71
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND
REAR AXLE SHAFT REASSEMBLING INFORMATION ......................................................... 7-73
GEARSHIFT LEVER ................................................................................................................. 7-74
CONSTRUCTION ............................................................................................................. 7-74
REMOVAL AND DISASSEMBLY .................................................................................... 7-75
INSPECTION .................................................................................................................... 7-76
REASSEMBLY AND REMOUNTING ............................................................................... 7-77
CABLES .................................................................................................................................... 7-79
REMOVAL AND INSTALLATION .................................................................................... 7-79
CABLE PLAY ADJUSTMENT .......................................................................................... 7-83