8 SHOCK ABSORBER, SWINGARM 4 Caution Risk of injury Parts of the shack absorber will move around if the shock absorber is detached incorrectly. ‘The shock absorber i filled with highly compressed nitrogen. Please follow the description provided. © Info ‘The high-speed setting can be seen during the fast compression of the shock absorber, = Turn adjusting screw @ all the way clockwise with a socket wrench. Info To not loosen fitting @. = Turn counterclockwise by the number of turns corresponding to the shock absorber type, Guideline Compression damping, high-speed Comfort 2tums Standard TS turns Sport Tum © Info T Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Caution Risk of injury Parts of the shack absorber will move around if the shock absorber is detached incorrectly. ‘The shock absorber is filled with highly compressed nitrogen, Please follow the description provided © Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. ~ Turn adjusting sew @ clockwise with 2 screwcriver up tothe last perceptible click Info To not toosen siting @. = Turn counterclockwise by the number af clicks corresponding to the shock absorber ‘ype. Guideline 10002810 Compression damping, low-speed Comfort Ta clicks Standard 15 clicks Sport 12 clicks Info [Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing.8 SHOCK ABSORBER, SWINGARM 35 Caution Risk of injury Parts of the shack absorber will move around if the shock absorber is detached incorrectly. ‘The shock absorber i filled with highly compressed nitrogen. Please follow the description provided. ~ Turn adjusting srew @ clockwise up tothe lst perceptibe click = Turn counterclockwise by the numberof clicks cortesponding to the shock absorber ‘ype. Guideline Rebound damping Comfort TS clicks Standard TB clicks Sport T2 clicks © Info TH Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Preparatory work = Raise the motorcycle with the lift stand. (© p. 9) Main work = Measure the distance ~ as vertically as possible ~ between the rear axle and fixed point such as a mark on the side cover. @ | ~ Moke a note ofthe value as dimension @ 49098810 Finishing work = Remove the motorcycle from the lft stand. (© p. 9) = Measure distance @ of rear wheel unloaded. (= p. 35) = Hold the motoreycle upright withthe aid ofan assistant. = Measure the estance between the rear axle an the fixed point again, ® | ote down the value as dimension @. Info TL The static sag is the difference between measurements @ and @. = Check the static sag. Static sag 30 mm (1.18 in) » Ifthe static sag is less or more than the specified value: = Adjust the spring preload of the shock absorber. (-* p. 36) 40988-108 SHOCK ABSORBER, SWINGARM 36 8.6 Checking the riding sag of the shock absorber — Messure distance @) of ear whee! unloaded. (= p. 38) = With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in @ normal sitting position (feet on footrests) and bounces up o and down a few times. 7 The rear wheel suspension levels out = Another person now measures the distance between the rear axle and the fixed point. = Note down the value as dimension @. Info T The riding sag isthe citference between measurements @ and @. = Check the riding sag. Riding sag 100 mm (3.94 in) » Ifthe riding sag differs from the specified measurement: = Adjust the riding sag. ("2 p. 37) 490990-10 Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filed with highly compressed nitrogen. = Please follow the description provided Preparatory work = Raise the motorcycle with the lift stand. (% p. 9) = Remove the shock absorber. (© p. 37) ~ After removing the shock absorber, clean it thoroughly Main work = Measure the full spring length while itis under tension and note down the value. = Loosen retaining ring @. Turn adjusting ring @ until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T1068) (= p. 176) = Measure the overall spring length while the spring is not under tension = Tighten the spring by turning adjusting ing @ to measurement @. Guideline Spring preload Standard Tm (039i) Info I The spring preload isthe difference between the relaxed spring length and the tensioned spring length. Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. 40195110, = Tighten screw @ ishing work = Install the shock absorber. (! p. 37) = Remove the motorcycle from the lift stand. (= p. 9)8 SHOCK ABSORBER, SWINGARM 3 Preparatory work = Raise the motorcycle with the lift stand. (© p. 9) — Remove the shock absorber. (82 p. 37) = After removing the shock absorber, clean it thoroughly Main work = Choose and mount a suitable spring. Guidetine Spring rate Weight of rider: < 45 kg (< 99 1b.) [30 Nimm (171 Ibfin) = Weight of rider: 45... 65 kg (99... | 35 Nimm (200 Ibvin) i2i ib) Weight of rider: > 55 kg “40 Nimm (228 Ibfin) 20029210 @ 121 1b) Info TL The spring cate is shown on the outside ofthe spring. ‘Smaller weight differences can be compensated by changing the spring preload. Finishing work = Install the shock absorber. (/ p. 37) = Remove the motorcycle from the lift stand. (& p. 9) = Check the static sag of the shock absorber. (= p. 35) = Check the riding sag of the shack absorber. (5 p. 36) = Adjust the rebound damping of the shock absorber. ("* p. 35) Preparatory work = Raise the motorcycle with the lift stand. (© p. 9) Main work = Remove screw @ and lover the rear wheel with the swingarm as far as possible without blocking the rear wieel, Fc the ear wheel inthis position ~ Remove screw @, push splash protector @ to the side, and remove the shock absorber. Main work Push splash protector @ to the side and postion the shock absorber. Mount and tighten scrow ®. Guideline Screw, top shock absorber | MI SO Nm] betta 2a (44.3 If ft) = Mount and tighten screw @ Guideline Seren, btom shock | WI2 BO Nm | Uoetia® 2a aocorer (aa tf ishing work = Remove the motorcycle from the lift stand. (= p. 9)8 SHOCK ABSORBER, SWINGARM 38 Caution Risk of injury Parts of the shack absorber will move around if the shock absorber is detached incorrectly. ‘The shock absorber i filled with highly compressed nitrogen. Please follow the description provided. Condition The shock absorber has been demounted. = Remove the spring. (© p. 38) aacsnt = Disassemble the damper. (© p. 39) = Disassemble the piston rod. (© p. 40) = Disassemble the seal ring retainer. (© p. 41) = Check the damper. (© p. 42) Disassemble the rebound adjuster. (© p. 42) = Remove the heim joint. (®2 p. 43) = Install the heim joint. (© p. 44) — Assemble the rebound adjuster. (© p. 45) = Assemble the seal ring retainer. (© p. 45) = Assemble the piston rod. (= p, 46) = Assemble the damper. (= p. 47) = Install the spring. (© p. 52) Concition ‘The shock absorber has been demounted = Clamp the shock absorber in @ bench vise using soft jaws. i = Measure and note down the spring length ina preloaded state A = Loosen sorew @. = Turn adjusting ring @ until the spring is no longer under tension, e Hook wrench (T1068) (™ p. 176) 202136:10 ~ Remove spring retainer @ and washer @ = Remove the spring. 20109810,8 SHOCK ABSORBER, SWINGARM 39 of | jee YE. 201101-10, 20110210 f201103-10 ~ Rotate adjusting ring @ with washer @ upward and remove 202137210 Preparatory work = Remove the spring. (= p. 38) Main work eg = Note down the present state of rebound damping @ anc compression damping @ = Completely open the adjusters af the rebound damping and compression damping. = Remove protection cap @ of the reservoir. = Slowly unscrew screw @. 7 The pressurized nitrogen is bled off. = Remove screw @. Drain the i = Remove protection cap @. = Push in seal ring retainer @ ~ Remove lock ring @. Info To not scratch the inner surface,8 SHOCK ABSORBER, SWINGARM 40 7 al 20110410 Go = Remove the piston rod. Drain the remaining oil = Remove compression adjuster @. Remove the spring and piston. ‘e 20110610 201055-10, er Use soft jaws. = Remove nut @. > = Remove rebound shim stack @. f ons ‘© Info together. = Remove piston © = Remave compression shim stack @ Info I Guide the compression shim stack onto a screwdriver and put them aside together. = Remove steeve @ = Remove rebound shim stack @. Info I Guido the retouna shim stack onto a screwdriver and put them aside together.8 SHOCK ABSORBER, SWINGARM a ~ Remove piston @. ~ Remove compression shim stack @. we Info Guide the compression shim stack onto a screwdriver and put them aside together. 20105610, ~ Remove rebound washer @. \ _—e— cep '201067-10. = Remove protection cap @ and rubber butter @. 20106810 Preparatory work — Remove the spring. (® p. 38) — Disassemble the damper. (© p. 39) — Disassemble the piston rod, (°* p. 40) Main work = Remove rebound rubber @. = Remove washer @. = Remove sal ring @. = Remove washer @ from seal ring @.8 SHOCK ABSORBER, SWINGARM 2 — Remove washer @ ~ Remove O-ring @. = Remove dust boot @. 200787-10 Preparatory work = Remove the spring (8 p. 38) = Disassemble the damper. (™ p. 39) ~ Disassemble the piston rd. (© p. 40) Main work = Clamp the piston rd into vse. = Remove piston rod adapter @. = Remove rebound needle @ = Remove rebound adjuster @. Pin wrench (T1218) (© p. 177) = Remove adjusting screw @. Condition The damper has been disassembled. = Measure the inside diameter on both ends and in the middle of the damper car- tidge, Damper cartridge Minimum diameter 46.10 mm (1.815 in) >If the measured value is greater than the specified value: = Replace the damper cartridge. = Check the damper cartridge for damage and wear. pone > If there is damage or wear: = Replace the damper cartridge. = Check the heim joint for damage and wear. » If there is damage or wear: = Replace the heim joint.8 SHOCK ABSORBER, SWINGARM 43 ——S 20112310 20081310, ~ Measure the diameter of the piston rod. Piston rod Diameter 317.95 mm (= 0.7067 in) » Ifthe specified value was not attained: = Replace the piston rod. — Measure the run-out of the piston rod Piston rod Run-out 0.03 mm (0.0012 in) » Ifthe measured value is greater than the specified value: = Replace the piston rod. = Check the piston rod for damage and wear. >If there is damage or wear: = Replace the piston rod. = Check the piston rings for damage and wear. » If damage or a bronze-colored surtace is visible: = Replace the piston rings. Info TThe steps are identical on the upper and lower heim joints. 21119110 Condition The shock absorber has been demounted. = Clamp the shock absorber in bench vise using soft jaws. = Remove both collar bushings @ of the heim joint using a pin. = Remove seal rings @ on both sides.8 SHOCK ABSORBER, SWINGARM 44 & = Press the heim joint against a lock ring using the special tool Pressing tool (112078) (© p. 177) ~ Remove the second lok ring @ ~ Place special to! @ underneath and press out heim joint @ using special teal @ Pressing tool (112078) (™ p. 177) I The steps are identical on the upper and lowe heim joints ~ Position the new heim joint @ and the special tool. Pressing tool (T1206) (= p. 177) ~~ Press in the heim joint all the way. = Press the heim joint against the lock ring using the special tool Pressing tool (112075) (™ p. 177) = Mount the second lock ring @. = Mount seal rings @ on both sides. zous.1t8 SHOCK ABSORBER, SWINGARM 45 I 20112910, 2 ~ Postion both colar bushings @ and press in = Lubricate the thread of adjusting screw @. Lubricant (T7152) ( p.170) Screw in the adjusting screw by several full turns. Lubricate the O-ring of rebound adjuster @. Lubricant (T158) (= p. 170) ‘Mount and tighten the rebound adjuster. Guidetine Screw sleave Miaxt 18m (13.3 If fo ‘Screw out the adjusting screw of the rebound adjuster all the way counterclockwise, Lubricate the lower end of the rebound needle. Lubricant (T158) (= p. 170) Slide rebound needle @ into the piston rod. Mount and tighten piston rod adapter @. Guideline Piston rod adapter Max 30Nm Loctite® 2701 (22.1 Ibe tt Mount ust beot @ with the special too Mounting sleeve (T1204) (=* p. 177) Grease the sealing lp of the dust boot. Lubricant (7625) p. 170) Grease the O-ring groove. Lubricant (7158) (& p. 170) Mount O-ring @. Mount washer @8 SHOCK ABSORBER, SWINGARM 48 ~ Position washer @ on seal ring @. Grease the seal rng and mount withthe washer facing downward Lubricant (S11) p. 170) Mount washer @. Mount rebound rubber @. Preparatory work = Assemble the seal ring retainer. (© p. 45) = Assemble the rebound adjuster. (© p. 45) Main work = Clamp the piston rod into a vise. Guideline 44) || =: = Mount rubber butter @ and protection cap @. 201071-10] — Grease the dust boot and slide seal ring retainer @ onto the piston rod. Lubricant (7625) (= p. 170) = Remove the special too Mount rebound washer @. 1 = Mount compression shim stack @ with the smaller shims facing downward. - Grind piston @ on both sides, using 1200 grit sandpaper on a surfacing plate. = Clean the piston. = Mount the piston, — ‘e Guideline view @ Top view of piston view @ Bottom view of piston 20107310, sees ee 88 SHOCK ABSORBER, SWINGARM 4 = Mount repoun shim stack @ withthe smaller shims atthe top 2 ~ Mount sleeve @. 20107410 Mount compression shim stack @ with the smaller shims at the bottom. a /—o 201075110 ~ Grind piston @ on both sides ona surtace plate using 1200 grit sandpaper. 9 = Clean the piston. Guideline ono Top view of piston view® Bottom view of piston 20110810 — Mount the lower rebound washer @ and washer @. Info I The washer centers the lower rebound washer. ~ Mount the upper rebound washer @® = Mount and tighten nut @ Guideline pone ‘Nut, piston rod MiOxI 301Nm (22.1 tor tb Preparatory work = Assemble the seal ring retainer. (© p. 45) = Assemble the rebound adjuster. (© p. 45) = Assemble the piston rod." p. 46) Main work — Slide the spring and piston onto compression adjuster @. = Grease the O-ing Lubricant (7158) p. 170) = Grease the threads. Lubricant (T7158) p. 170) = Mount and tighten compression adjuster @. 20107620} Guideline Compression damping adjuster MBIxL 50Nm (36.9 tot th8 SHOCK ABSORBER, SWINGARM 201123-10, of f201124-10, 201125210 ce — Mount screw @ but do not tighten yt = Grease the O-ing ofthe seal rng retainer. Lubricant (T158) (= p. 170) = Fill the damper tube approximately half way. Shock absorber fluid (SAE 2.5) (5018075151) (= p. 169) = Carefully mount the piston rod. = Mount seal ring retainer @ and slide it under the ring grove. = Mount tock ing @. © Info To not scrateh the inner surface. = Pullout the piston rod in order thatthe seal rng retainer fits closely against the Tock ring = Mount protection cap @ ofthe damper cartridge = Bleed and fil the damper. (=p. 49) = Fill the damper with nitrogen. (= p. 51) ~ Mount protection cap @ ofthe reservoir Alternative 1 ~ Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click. = Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline F Rebound damping Comfort 18 clicks f201100-11 ‘Standard 15 clicks Sport 12 clicks — Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click, = Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 16 clicks Standard 15 clicks Sport 12 clicks ~ Turn aajuting serew @ clockwise with 2 socket wrench unt it stops, = Turn counterclocse by the numberof tums cortesponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport tum8 SHOCK ABSORBER, SWINGARM 49 Alternative 2 Warning Danger of accident Modifications to the suspension setting may seri- ously alter the handling characteristic. Extreme modifications to the suspension setting may cause @ serious deterioration in the handling characteristic and overload components. ~ Only make adjustments within the recommended range. — Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. ~ Set adjusting screws @, © and @ in the positions determined when disas- sembling, © Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound damping and compression damping = Remove the screw from the filling port. ‘Mount adapter @) on the damper. Info DB Hanc:-tighten only without using a tool. ~ Connect adapter @ to connector @ of the vacuum pump. Vacuum pump (T12408) (= p. 177) 20111510] — Clamp the damper with soft jaws or hold it as shown in the photo, Info TH ciamp the damper only lightly. The filling port must be located at the highest point The piston rod moves in and out during filling: do not immobilize it by hold ing it with your hand. Position the control lever as shown in the photo. Control lever External tank @ is set to Closed; Damper @ is set to Vacium; and Oil reservoir @ is set to Vacuum. ~ retivate ont switen @ ‘~% The suction process begins. 7 Pressure gauge @ drops tothe required valve. Guideline Spring rate 2 Weight of rider: <5 kg (299 1b) [30 Nim (171 Ibi Weight of rider: 45... 55 kg (99... | 35 Nimm (200 iin 121tb) Weight of rider > 55 kg “40 Winn (228 tnd {201098-11. (> 121 Ib) = Mount washer @ and spring retainer @. Aernative t = Tighten the spring by turning adjusting ring @ tothe measurement. Er Guideline Spring preload Standard TOmm (0.39 0) Hook wrench (T1068) p. 176) Alternative 2 ee Warning Danger of accident Modifications to the suspension setting may seri- ously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. = Only make adjustments within the recommended range. = Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.8 SHOCK ABSORBER, SWINGARM 83 = Tighten the spring by turning adjusting ring @ tothe value measured when it was removed. Hook wrench (T1088) (© p. 176) = Tighten screw @ Guideline [Serew, shock absorber adjusting ving Me 5 Nm (3.7 Wot)