GENERAL
Maximum tire mileage and good handling qualities are directly related to care given wheels and tires. Wheels and tires should be regularly inspected for wear. If handling problems occur, see 1.25 TROUBLESHOOTING for possible causes.
Always keep tires inflated to the recommended pressure and balance the wheel whenever a tire or tube is replaced.
REMOVAL
1. Place the motorcycle on a hydraulic center stand with the front wheel raised off the ground.
2. Inspect wheel bearings. See 2.8 SEALED WHEEL BEARINGS.
3. If present, carefully cut two cable straps to release front wheel speed sensor cable and front fender tip lamp wires from brake hose to left brake caliper.
4. See Figure 2-2. On ABS equipped motorcycles, release front wheel speed sensor cable from clip as follows:
a. Push on lip at rear of clip to disengage from bracket.
b. Rotate tab (stamped ABS) rearward until clip is per-pendicular to bracket and remove cable.
5. Remove two brake caliper mounting screws (with cable clip/bracket if ABS equipped). Slide brake caliper straight down to remove from brake disc. Using thru hole, cable strap caliper to rail of engine guard, so that it is not sus-pended by brake hose.
6. Remove brake caliper on right side of wheel.
NOTE
Do not operate the front brake hand lever with the front wheel removed or the caliper pistons may be forced out. Reseating pistons requires disassembly of the brake caliper.
7. See Figure 2-3. Insert screwdriver or steel rod through hole in axle on right side of motorcycle. While holding axle stationary, remove the axle nut and flat washer on the left side.
8. Loosen the two axle holder nuts at bottom of right side fork slider.
1
2
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1. Push lip to disengage 2. Push tab to engage
Figure 2-2. Front Wheel Speed Sensor Cable Clip (ABS Equipped)
9. Using a soft mallet, gently tap end of axle towards right side of motorcycle. Catching external spacer(s), pull axle free of fork sliders, front wheel speed sensor (if ABS equipped), and wheel hub.
NOTE
If ABS equipped, never pull wheel speed sensor cable taut or use to retain wheel, axle or other components. Always keep wheel speed sensor (and ABS encoder bearing) away from magnetic fields (such as magnetic parts trays, magnetic base dial indicators, alternator rotors, etc.) or damage will occur.
10. Move wheel to bench area.
NOTE
Do not operate the front brake lever with the front wheel removed or the caliper pistons may be forced out. Reseating pistons requires disassembly of the caliper.
11. If necessary, remove five screws to release brake discs from hub.
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17
15
10 4
12 6
14 9
5
7 8
13
4 2
3 1
3 11
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10.
1. Axle nut Spacer sleeve
2. Flat washer 11.Axle
12.
3. External spacer Brake disc (left side)
4. Standard bearing 13.T40 TORX screw (10)
14.
5. ABS encoder bearing Brake disc (right side)
6. Front wheel speed sensor 15.Laced wheel
16.
7. Cable clip Cast wheel
8. Clip bracket 17.Slotted cast wheel
9. Spacer washer
Figure 2-3. Front Wheel (Exploded View)
CLEANING AND INSPECTION
1. Thoroughly clean all parts in solvent (wheel speed sensor and bearings excepted) and inspect for damage or excessive wear.
2. Replace brake discs if warped or badly scored. Measure disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc.
INSTALLATION
1. If removed, install five new screws to fasten brake discs to hub. Alternately tighten screws to 16-24 ft-lbs (22-33 Nm).
2. Place wheel into position between fork sliders with the valve stem on the right side of the motorcycle.
3. Apply a light coat of LOCTITE ANTI-SEIZE lubricant to axle, bearing bores and bore of spacer sleeve.
4. Slide axle through right fork slider and external spacer into wheel hub.
NOTE
Be sure that grooves on external spacer(s), or index pin on front wheel speed sensor (if ABS equipped), are on the out-board side. If motorcycle is not ABS equipped, external spacers on left and right side of wheel hub are interchangeable.
5. When axle emerges from hub on left side of wheel, push it through front wheel speed sensor (if ABS equipped) or second external spacer, and then through left fork slider.
6. Install flat washer and axle nut.
7. See Figure 2-4. If ABS equipped, rotate front wheel speed sensor in a counter-clockwise direction until index pin makes contact with shoulder on left fork slider.
8. Insert screwdriver or steel rod through hole in axle on right side of motorcycle. While holding axle stationary, tighten axle nut to 60-65 ft-lbs (81.4-88.1 Nm).
9. Push right fork slider inboard until it contacts external spacer, and then holding it in this position, tighten axle holder nuts to 132-180 in-lbs (14.9-20.3 Nm).
10. Install left side brake caliper as follows:
a. Install caliper at bottom of brake disc. Pry inner and outer brake pads back for additional clearance, if necessary.
b. Slide brake caliper straight up until holes are aligned with lugs on fork slider. Start two mounting screws (with cable clip/bracket if ABS equipped).
NOTE
Be sure that tab (stamped ABS) on clip is installed in slot of bracket from inboard side. Clip cannot be installed once mounting screws are started.
c. Alternately tighten mounting screws to 28-38 ft-lbs (37.9-51.5 Nm)
d. Repeat applicable steps to install caliper on right side of wheel.
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
11. Depress front brake hand lever several times to set brake pads to proper operating position within caliper.
12. If ABS equipped, install two new cable straps as follows:
a. Install cable strap 2.5 in. (63.5 mm) above the bottom brake hose crimp capturing front wheel speed sensor cable and brake hose.
b. Install cable strap 2.5 in. (63.5 mm) below the top brake hose crimp capturing front wheel speed sensor cable, brake hose and front fender tip lamp wires, if equipped.
13. If ABS equipped, install front wheel speed sensor cable in clip as follows:
a. Rotate tab (stamped ABS) until clip is perpendicular to bracket and install cable.
b. Rotate tab forward until clip is inline with bracket and then apply pressure to tab until lip engages. Gently pull on cable to verify that clip is properly installed.
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Figure 2-4. Front Wheel Speed Sensor Index Pin (ABS Equipped)