PERBAIKAN DAN PERAWATAN BERKALA

SISTEM SUSPENSI SEPEDA MOTOR

Disusun Oleh :
I GUSTI KADE SILADANA. S.Pd. T
 NIP. 19810416 200804 1 001

GURU MATA PELAJARAN PRODUKTIF

TEKNIK OTOMOTIF

SMK NEGERI 3 TABANAN

Alamat : Jl. Kahyangan Bunut Puhun Bantas
Selemadeg Timur Tabanan Bali
 

SM  NE ERI 3 TAB NAN

ME AKUKA  PERBAI AN DAN PERAW TAN BERKALA
SISTEM SUSPENSI SE EDA M TOR
elas : IX J BSHEET Wa tu : 4 x 45 Menit

SU PENSI D PAN

 
TUJU N PEMB LAJARAN PRAKTEK :

1.  Siswa mamp   memveri ikasi kiner 

 ja sistem uspensi se peda motor melalui rosedur
 pe eriksaan sesuai SOP  Manual Service). 

2.  Siswa mamp menerap an prosedur perawatan berkala istem sus ensi seped a motor
sesuai SOP ( anual Ser  ice).

 
ALAT DAN BA AN :

1.  Se eda Motor Yamaha J  piter MX 135 SE-S

2.  Al t-Alat Tan an ( Hand
 Hand Tools)
3.  SS  Untuk Melepas Bau L
4.  Gemuk atau Pelumas
5.   Nampan (Wa ah)
6.  Buku Manual Servis Sep da Motor amaha Ju iter MX 135 SE-S
7.  M  jun (Kain ap)
8.  Ba ok Kayu
 

KESE AMATA KERJA

1.  Gunakan pera atan sesuai dengan fu gsinya.

2.  Mintalah Buk   Manual Servis Sepe a Motor s suai Type epeda Motor yang di unakan
dalam kegiata  praktiku .
3.  Ik  tilah instruksi dari instruktur ata  pun prosedur kerja yang tertera  pada Jobs eet atau
Buku Manual Servis Sep da Motor ang bersangkutan.
4.  Mintalah ijin dari Instru tur anda ila hendak melakuka  pekerjaa   yang tida tertera
 pa a Jobsheet.
5.  Be doalah sebelum mem lai kegiat n praktiku  agar se uanya berl ngsung la car dan
sesuai denga   target pe capaian k  mpetensi erbaikan an peraw tan berkal sistem
su  pensi sepe a motor.
 

LANGKAH KE JA :

1.  Ce matilah ta apan tugas atau kegia an praktik  m sistem s spensi secara seksam .
2.  Identifikasi peralatan dan bahan pra tikum secara cermat, fektif dan eefisien m ngkin.
 

3.  Mintalah penjelasan instruktur mengenai hal-hal yang belum jelas terkait materi
 pembelajaran praktek sistem suspensi yang akan dilakukan.
4.  Lakukan langkah pembongkaran, pemeriksaan dan pemasangan sistem suspensi sesuai
dengan SOP pada Buku Manual Servis Sepeda Motor sesuai Type Sepeda Motor yang
digunakan, meliputi :
a.  Langkah Pembongkaran :
1)  Melepas roda depan
2)  Melepas front cowling
3)  Melepas side cowling (kiri-kanan)
4)  Melepas center panel dan inner panel
5)  Melepas Brake Caliper Assembly (Caliper Rem Depan)
6)  Melepas Brake Hose Clamp (clem selang rem)
7)  Melepas front fender bolt, collar. Washer dan front fender (spakbor depan)
8)  Melepas front fork cap bolt (tutup tabung garpu depan)
9)  Melepas lower bracket finch bolts (baut pengunci bracket)
10) Melepas Melepas kaki-kaki depan (tabung suspensi depan)
11) Melepas pegas suspensi dan mengeluarkan oli suspensi depan
12) Melepas dust seal (seal debu) dan oil seal clip (klip pengunci oil seal)
13) Melepas dumper rod assembly bolts dan copper washer
14) Melepas inner tube, rebound spring dan dumper rod.
15) Melepas oil seal
Identifikasi dan Tuliskan nama-nama komponen suspensi yang ditunjukkan pada
gambar berikut :
Nomor Komponen :

1.  ..................................................

2.  ....................................................

3.  ....................................................

4.  ....................................................
5.  ....................................................

6.  ....................................................

7.  ....................................................

8.  ....................................................

9.  ....................................................

10. .....................................................
 

 
 b.  Langkah Pemeriksaan :
Item Pemeriksaan Hasil Pemeriksaan Simpulan Petunjuk
(Coret yang tidak perlu) Pemeriksaan/Pengukuran
1.  Permukaan Cacat / Tidak Cacat
lapisan vernekel
tabung suspensi

dalamluar
dan (inner(outter
tube)
tube)
2.  Keolengan tabung Oleng / Tidak Oleng
suspensi
(Limit: 0,20 mm)
3.  Konsisi Seal debu Cacat / Tidak Cacat
dan seal oli
4. Kondisi Dumper Cacat / Tidak Cacat
Rod (Peredam)

5. Panjang pegas  Normal / Abnormal

suspensi
STD = 295.3 mm
Limit = 289.4 mm 

c.  Langkah Pemasangan :

1.  Pasang inner tube, rebound spring dan dumper rod
2.  Lumasi inner tube dengan oli suspensi 10W
3.  Kencangan baut inner tube sesuai dengan spesifikasi momen (23 Nm)
4.  Pasang oli seal dan oil seal clip
5.  Pasang kaki-kaki depan (tabung suspensi pada dudukan garpu depan)
6.  Pasang baut pengunci tabung suspensi pada bracketnya.
7.  Masukkan oli suspensi sebanyak 0.064 Liter (rekomendasi spesifikasi oli 10W)
8.  Masukkan pegas suspensi
9.  Pasang fork cap bolts (baut tutup garpu depan) dan kencangkan (50 Nm)
10. Kencangkan baut bracket pengunci tabung suspensi dengan spesifikasi 43 Nm.
11. Memasang front fender, collar, bolr and washer, lalu memasang roda depan
12. Memasang Brake Caliper Assembly dan Brake Hose Clamp (clem selang rem)
13. Memasang center panel dan inner panel, side cowling dan front cowling.
d.  Memeriksa kinerja suspensi
e.  Membersihkan kotoran dan oli yang menempel pada kompenen suspensi dan firing/body
sepeda motor dengan kain lap (majun).

TUGAS SETELAH SELESAI PRAKTEK :

1.  Buatlah laporan kegiatan praktek saudara secara ringkas dan jelas !
2.  Buatlah rangkuman pengetahuan dan keterampilan yang anda peroleh setelah mengikuti
 pembelajaran teori dan praktek sistem suspensi sepeda motor !
 

SM  NE ERI 3 TAB NAN

ME AKUKA  PERBAI AN DAN PERAW TAN BERKALA
SISTEM SUSPENSI SE EDA M TOR
elas : IX J BSHEET Wa tu : 4 x 45 Menit

SUS ENSI BE AKANG MONO S OCK)

 
TUJU N PEMB LAJARAN PRAKTEK :

1.  Siswa mamp   memveri ikasi kiner 

 ja sistem uspensi se peda motor melalui rosedur
 pe eriksaan sesuai SOP  Manual Service). 

2.  Siswa mamp menerap an prosedur perawatan berkala istem sus ensi seped a motor
sesuai SOP ( anual Ser  ice).

 
ALAT DAN BA AN :

1.  Se eda Motor Yamaha J  piter MX 135 SE-S

2.  Al t-Alat Tan an ( Hand
 Hand Tools)
3.  SS  Untuk Melepas Bau L
4.  Gemuk atau Pelumas
5.   Nampan (Wa ah)
6.  Buku Manual Servis Sep da Motor amaha Ju iter MX 135 SE-S
7.  M  jun (Kain ap)
8.  Ba ok Kayu

 
KESE AMATA KERJA

1.  Gunakan pera atan sesuai dengan fu gsinya.

2.  Mintalah Buk   Manual Servis Sepe a Motor s suai Type epeda Motor yang di unakan
dalam kegiata  praktiku .
3.  Ik  tilah instruksi dari instruktur ata  pun prosedur kerja yang tertera  pada Jobs eet atau
Buku Manual Servis Sep da Motor ang bersangkutan.
4.  Mintalah ijin dari Instru tur anda ila hendak melakuka  pekerjaa   yang tida tertera
 pa a Jobsheet.
5.  Be doalah sebelum mem lai kegiat n praktiku  agar se uanya berl ngsung la car dan
sesuai denga   target pe capaian k  mpetensi erbaikan an peraw tan berkal sistem
su  pensi sepe a motor.
 

LANGKAH KE JA :

1.  Ce matilah ta apan tugas atau kegia an praktik  m sistem s spensi secara seksam .
2.  Identifikasi peralatan dan bahan pra tikum secara cermat, fektif dan eefisien m ngkin.
 

3.  Mintalah penjelasan instruktur mengenai hal-hal yang belum jelas terkait materi
 pembelajaran praktek sistem suspensi yang akan dilakukan.
4.  Lakukan langkah pembongkaran, pemeriksaan dan pemasangan sistem suspensi sesuai
dengan SOP pada Buku Manual Servis Sepeda Motor sesuai Type Sepeda Motor yang
digunakan, meliputi :
a.  Langkah Pembongkaran :
1)  Melepas Rear Cowling (Kiri dan Kanan)
2)  Melepas Muffler (Knalpot)
3)  Melepas Rear Wheel (Roda Belakang)
4)  Melepas Drive Chain Case (Tutup Rantai Penggerak)
5)  Melepas Brake Torque Rod to Swing Arm
6)  Melepas Rear shockbreaker Nuts (Mur)
7)  Melepas Rear shockbreaker Bolts (Baut)
8)  Melepas Rear shockbreaker assembly
9)  Melepas Swing Arm Pivot Shaft Nut (Mur - Baut)
10)  Melepas Collar
11)  Melepas Swing Arm Pivot Shaft (Poros Swing Arm)
12)  Melepas Swing Arm

Identifikasi dan Tuliskan nama-nama komponen suspensi yang ditunjukkan pada

gambar berikut :
Nomor Komponen :

1.  ..................................................

2.  ....................................................

3.  ....................................................

4.  ....................................................

5.  ....................................................

6.  ....................................................

7.  ....................................................
 

 b.  Langkah Pemeriksaan :

Item Pemeriksaan
Pemeriksaan Shock Absorber
Hasil Pemeriksaan Simpulan
(Coret yang tidak perlu)
Batang Absorber : Cacat / Tidak Cacat
Oli Bocor : Ya / Tidak
Pegas : Normal / Tidak Normal
Bushing : Cacat / Tidak Cacat

Pemeriksaan Visual (fisik) Baut : Bagus / Tidak Bagus

Swing Arm Cacat / Tidak Cacat

Keolengan Poros Swing Arm

Oleng / Tidak Oleng

Kondisi Bushing Swing Arm Cacat / Tidak Cacat

Kondisi Washer Swing Arm Cacat / Tidak Cacat

c.  Langkah Pemasangan :

1.  Pemasangan Swing Arm
2.  Pemasangan Swing Arm Pivot Shaft (Poros Swing Arm)
3.  Pemasangan Collar
4.  Pemasangan Swing Arm Pivot Shaft Nut (Mur - Baut)
5.  Pemasangan Rear shockbreaker assembly
6.  Pemasangan Rear shockbreaker Nuts (Mur)
7.  Pemasangan Rear shockbreaker Bolts (Baut)
8.  Pemasangan Brake Torque Rod to Swing Arm
Ar m
9.  Pemasangan Drive Chain Case (Tutup Rantai Penggerak)
10. Pemasangan Rear Wheel (Roda Belakang)
11. Pemasangan Muffler (Knalpot)
12. Pemasangan Rear Cowling (Kiri dan Kanan)
d.  Memeriksa kinerja suspensi belakang (monoshock )
e.  Membersihkan kotoran dan oli yang menempel pada komponen suspensi, tutup rantai
 penggerak, cowlings dan muffler (knalpot) sepeda motor dengan kain lap (majun).

TUGAS SETELAH SELESAI PRAKTEK :

1.  Buatlah laporan kegiatan praktek saudara secara ringkas dan jelas !
2.  Buatlah rangkuman pengetahuan dan keterampilan yang anda peroleh setelah mengikuti
 pembelajaran teori dan praktek sistem suspensi sepeda motor !

LAMPIRAN : BUKU MANUAL SERVIS YAMAHA JUPITER MX 135 SE-SERIES

 

T135SE
T135S

SER
SERVIC
VICE
E MAN
MANUAL
UAL

5YP-F8197-E0
 

EAS00000

T135SE/T135S
SERVICE MANUAL
 ©2005 by Yamaha Motor Co., Ltd.
First edition, April, 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
 

EAS00002

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT
IMPORTANT MANUAL INFORMA
INFORMATION
TION

Particularly important information

information is distinguishe
distinguished
d in this manual by the following.

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT!

ALERT! YOUR SAFETY IS
INVOLVED!

 w Failure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.

c                      
C A CAUTION indicates special
special precautions
precautions that must be taken to avoid damage
damage to
the vehicle.

NOTE: A NOTE provides key information to make procedures

procedures easier or clearer.
clearer.
 

EASF0001

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1:This is a chapter with its symbol on the upper right of each page.
2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the
chapter “Periodic inspection and adjustment” the 3 rd title appears.)
3rd title  3:This is a final title.

MANUAL
MANUAL FORMA
FORMAT
T
All of the procedures in this manual are organized in a sequential, step - by - step format. The informa-
tion has been compiled to provide the mechanic with a easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly
particularly important procedure 4 is placed between a line of mark “” or “” with each pro-
important procedure
cedure preceded by “8”.

IMPORTANT FEATURES
8Data and a special tool are framed in a box preceded by a relevant symbol 5 .
8An encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an align-
ment mark 7, the others being indicated by an alphabetical letter in a box 8 .
8A condition of a faulty component
component will precede an arrow symbol and the course of action required
required the
symbol 9 .

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
 

1 2 SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 8 indicate the subject of each
 3 4 chapter.

1 General information
CHK
ADJ ENG 2
 3 Specifications
Periodic checks and adjustments
4 Engine
5 6 5 Cooling system
6 Carburetor(s)
7 Chassis
COOL CARB 8 Electrical system
9 Troubleshooting
7 8
Symbols 0 to u indicate the following.

CHAS ELEC 0 Serviceable with engine mounted

9 0
TRBL
SHTG
 q w
e r
t y u d
q Filling fluid
w Lubricant
e Special tool
 r Tightening torque
t Wear limit, clearance
y Engine speed
u Electrical data
Symbols i to g in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
i Engine oil
o Gear oil
p Molybdenum-disulfide oil
a Wheel-bearing grease
s Lithium-soap-based grease
Molybdenum-disulfide grease

Symbols f to g in the exploded diagrams indi-

cate the following.
i o p
f Apply locking agent (LOCTITE ® )
g Replace the part

a s d

f g

LT
New
 

TABLE OF CONTENTS
EAS00011

GENERAL
GENERAL INFO
INFORMA
RMATION
TION
1
GEN
INFO

SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
CHK
ADJUSTMENTS ADJ 3
ENGINE ENG
4
COOL
COOLIN
ING
G SYS
SYSTE
TEM
M
ENG
5
CARBURETOR
CARB

6
CHASSIS
CHAS
7
ELECTRI
ELECTRICA
CAL
L SYS
SYSTEM
TEM
ELEC
8
TROUBLESHOOTING
9
TRBL
SHTG
 

FRONT FORK CHAS

EASF0054

FRONT FORK
1 Front fork cap bolt 0 Front fork cover (left)
2 Dust seal
 3 Oil seal clip
4 Oil seal
5 Fork spring
6 Damper rod
7 Inner tube
8 Outer tube
9 Damper rod bolt

43 Nm (4.3 m•kg, 31 ft•lb ) 1

7
5

2
 3
4

8
6

9
23 Nm (2.3 m•kg, 17 ft•lb )

7-30
 

FRONT FORK CHAS

EAS00649

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Stand the vehicl
vehicle
e on a level
level surface
surface..

 w
Securely support the vehicle so that there is
no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.

2. Re
Remmoveve::
9side cowlings (left and right)
9front cowling
9center panels
9inner panel
Refer to COVERS  in chapter 3.
“ ”

3. Re
Remmoveve::
9brake caliper assembly
9brake hose clamp
Refer to FRO
“FRONT
NT BRA
BRAKE
KE .”

9front wheel
Refer to FRONT WHEEL AND BRAKE
“

DISC . ”

4. Re
Remmoveve::
9front fender bolts
9washers

1 9 collars
9front fender 1

7-31
 

FRONT FORK CHAS

5. Remo
moveve::
1 9front fork cap bolt 1
(with a 10-mm hexagonal wrench)
6. Loose
sen:
n:
9lower bracket pinch bolt 2

 w
2
Before loosening the lower bracket pinch
bolt, support the front fork leg.

7. Remo
moveve::
9front fork leg

EAS00655

DISASSEMBLING THE FRONT FORK

LEGS
The following procedure applies to both of the
front fork legs.
1. Remo
moveve::
9fork spring

2. Drain:
1 9fork oil
NOTE:
Stroke the inner tube 1 several times while
draining the fork oil.

3. Remomove
ve::
9dust seal 1
9oil seal clip 2
(with a flat-head screwdriver)
c                      
C
Do not scratch the inner tube.

7-32
 

FRONT FORK CHAS

4. Re
Rem
move
ve::
9damper rod assembly bolt
9copper washer
NOTE:
While holding the damper rod assembly with a
10 mm hexagon nut/socket wrench 1 and the T-
handle 2, loosen the damper rod assembly bolt
 3.

T-handle
90890-01326

5. Re
Remmoveve::
9inner tube
9rebound spring
9damper rod
NOTE:
Pull out the inner tube and damper rod together.

6. Re
Rem move
ve::
9oil seal 1
2 Rag

7-33
 

FRONT FORK CHAS

EAS00657

1 CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
9inner tube 1
9outer tube 2

2 Bends/damage/scratches → Replace.
 w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2.Measure:
9spring free length  a
Out of specifications → Replace.

Spring free length

295.3 mm (11.63 in)
<Limit>: 289.4 mm (11.39 in)

3. Check:
9damper rod 1
Damage/wear → Replace.
1 →
Obstructions Blow out
sages with compressed air.all of the oil pas-
c                      
C
9The front fork leg has a built-in damper
adjusting rod and a very sophisticated inter-
nal construction, which are particularly sen-
sitive to foreign material.
9When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.

7-34
 

FRONT FORK CHAS

EAS00659

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.

 w
9Make sure the oil levels in both front fork 
legs are equal.
9Uneven oil levels can result in poor han-
dling and a loss of stability.

NOTE:
9When assembling the front fork leg, be sure to
replace the oil seal.
9Before assembling the front fork leg, make sure
all of the components are clean.

1. In
Inst
stal
all:
l:
9damper rod 1
9rebound spring
9inner tube 2
1
c                      
C
2 Allow the damper rod to slide slowly down
the inner tube 2 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.

2. Lu
Lubr
bric
icat
ate:
e:
9inner tube outer surface

Recommended lubricant
Fork oil 10W or equivalent

3. Tig
ight
hten
en::
9damper rod assembly bolt 1
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE ® 

7-35
 

FRONT FORK CHAS

NOTE:
Tighten the damper rod assembly bolt 1 while
holding the damper rod with the T-handle 2 and
a 10 mm hexagon nut/socket wrench 3.

T-handle
90890-01326

4. In
Inst
stal
all:
l:
9oil seal 1
(with the fork seal driver weight 2 and fork
seal driver attachment 3
 3)
Fork seal driver weight
90890-01184
Fork seal driver attachment
90890-01186

c                      
C
Make sure the numbered side of the oil seal
faces up.

NOTE:
9Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
9Lubricate the outer surface of the inner tube
with fork oil.
9Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to protect
the oil seal during installation.

5. In
Inst
stal
all:
l:
9oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube s groove.
’

7-36
 

FRONT FORK CHAS

6. Fill:
9front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.064 L (2.26 Imp.oz,
Imp.oz, 2.16
2.16 US oz)
Recommended oil
Fork oil 10W or equivalent

Front fork leg oil level  a (from the

top of the inner tube, with the inner
tube fully compressed and without
the fork spring)
104.5 mm (4.11 in)

NOTE:
9While filling the front fork leg, keep it upright.
9After filling, slowly pump the front fork leg up
and down to distribute the fork oil.

7. In
Inst
stal
all:
l:
9fork spring 1
NOTE:
Install the fork spring with the smaller pitch fac-
ing up.

EAS00662

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. In
Inst
stal
all:
l:
9front fork leg 1
9front fork cap bolt 2
Temporarily tighten the lower bracket pinch
bolt.
NOTE:
Pull up the inner tube until it is stopped, then
install the front fork cap bolt 2.

2. Tig
ight
hten
en::
9lower bracket pinch bolt 1
43 Nm (4.3 m·kg, 31 ft·lb)

9front fork cap bolt 250 Nm (5.0 m·kg, 36 ft·lb)

7-37
 

FRONT FORK CHAS

3. In
Inst
stal
all:
l:
9front fender 10 Nm (1.0 m·kg, 7.2 ft·lb)
4. In
Inst
stal
all:
l:
9front wheel
Refer to FRONT WHEEL AND BRAKE
“

DISC .
”

9brake hose clamp

9brake caliper assembly
Refer to FRO
FRONT
“ NT BRA
BRAKE
KE . ”

7-38
 

REAR SHOCK ABSORBER

ABSORBER ASSEMBLY
ASSEMBLY AND SWINGARM CHAS
REAR SHOCK ABSORBER ASSEMBL
ASSEMBLY
Y AND SWINGARM
1 Rear shock absorber
2 Brake torque rod
 3 Swingarm
4 Bushing
5 Swingarm pivot shaft
6 Drive chain case

46 Nm (4.6 m•kg, 33 ft•lb )

6
2

46 Nm (4.6 m•kg, 33 ft•lb )

4
 3

66 Nm (6.6 m•kg, 48 ft•lb )

4
LS

7-49
 

REAR SHOCK ABSORBER ASSEMBL

ASSEMBLY
Y AND SWINGARM CHAS
EAS00691/EAS00702

REMOVING THE REAR SHOCK

ABSORBER ASSEMBLIES AND
SWINGARM
1. Stan
Stand
d the vehicle
vehicle on a level
level surface
surface..

 w
Securely support the vehicle so that there is
no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.

2. Remo
move
ve::
9center panel
9rear cowlings (left and right)
Refer to REMOVING THE REAR COWL-
“

INGS  in chapter 3.

”

9muffler
“ ”
Refer to REMOVING THE ENGINE   in
chapter 4.
9rear wheel
Refer to REAR WHEEL
WHEEL AND BRAKE
“ BRAKE . ”

3. Remo
move
ve::
9drive chain case bolts
9drive chain case 1
1

4. Remo
moveve::
9cotter pin
9washer
9brake torque rod 1

7-50
 

REAR SHOCK ABSORBER

ABSORBER ASSEMBLY
ASSEMBLY AND SWINGARM CHAS
5. Re
Remmove
ve::
2
9rear shock absorber bolt (upper and lower)
1
9washer
9rear shock absorber nut (upper and lower)
 3 2
9washers
1 9rear shock absorber assembly 3

6. Me
Meas
asur
ure:
e:
9swingarm side play
9swingarm vertical movement

 ∫
a. Measure
Measure the
the tighteni
tightening
ng torque
torque of
of the
swingarm pivot shaft nut.
Pivot shaft nut
 å 66 Nm (6.6 m·kg, 43 ft·lb)

b. Meas
Measure
ure the
the swingarm
swingarm side play  å by mov-
side play

ing the swingarm from side to side.

c. If the swingarm
swingarm side
side play
play is out of specifi
specifica-
ca-
tion, check the spacers and bearings.
Swingarm side play (at the end of
the swingarm)
1 mm (0.04 in)

d. Check
Check the swingarm
swingarm vertica movement  ∫
verticall movement
by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
washer and bushings.


7-51

 
 REAR SHOCK ABSORBER ASSEMBL
ASSEMBLY
Y AND SWINGARM CHAS
7. Remo
move
ve::
 3 9swingarm pivot shaft nut 1
2 9washer 2
1 9swingarm pivot shaft 3
 3
9swingarm 4

EAS00695

CHECKING THE REAR SHOCK

ABSORBER ASSEMBLIES
The following procedure applies to both rear
shock absorber assemblies.
1. Check:
9rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
9rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
9spring
Damage/wear → Replace the rear shock
absorber assembly.
9bushings
Damage/wear → Replace.
9bolts
Bends/damage/wear → Replace.

7-52

 
 REAR SHOCK ABSORBER
ABSORBER ASSEMBLY
ASSEMBLY AND SWINGARM CHAS
EAS00707

CHECKING THE SWINGARM

1. Check:
9swingarm
Bends/cracks/damage → Replace.

2. Check:
9swingarm pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.

 w
Do not attempt to straighten a bent pivot
shaft.

3. Wash:
9swingarm pivot shaft
9washer
9bushings
Recommended cleaning solvent
Kerosene

4. Check:
9washer
Damage/wear → Replace.
9bushings
Damage/wear → Replace.

EAS00711/EAS00699

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLIES AND
SWINGARM
1. Lu
Lubr
bric
icat
ate:
e:
9swingarm pivot shaft

Recommended lubricant
Lithium-soap-based grease

7-53

 
 REAR SHOCK ABSORBER ASSEMBL
ASSEMBLY
Y AND SWINGARM CHAS
2. In
Inst
stal
all:
l:
9swingarm
9swingarm pivot shaft
9collar
9swingarm pivot shaft nut
66 Nm (6.6 m·kg, 48 ft·lb)
3. In
Inst
stal
all:
l:
9rear shock absorber assemblies
9rear shock absorber nuts
9rear shock absorber bolts
46 Nm (4.6 m·kg, 33 ft·lb)
4. In
Inst
stal
all:
l:
9brake torque rod (to swingarm)
16 Nm (1.6 m·kg, 12 ft·lb)
5. In
Inst
stal
all:
l:
9drive chain case
10 Nm (1.0 m·kg, 7.2 ft·lb)
6. In
Inst
stal
all:
l:
9rear wheel
Refer to REAR WHEEL
“ WHEEL AND BRAKE
BRAKE . ”

9muffler
Refer to REMOVING THE ENGINE   in
“ ”

chapter 4.
9rear cowlings (left and right)
Refer to INSTALLING THE REAR COWL-
“

INGS  in chapter 3.

”

7-54

 
 DRIVE CHAIN AND SPROCKETS CHAS
DRIVE CHAIN AND SPROCKETS
1 Rear wheel drive hub 0 Circlip
2 Driven sprocket q Drive sprocket cover
 3 Lock washer
4 Collar
5 Oil seal
6 Bearing

7
8 Master link
Drive chain
9 Drive sprocket

1
30 Nm (3.0 m•kg, 20 ft•lb )

2
 3

8 LS

4
9 6
0
5

7 Nm (0.7 m•kg, 5.0 ft•lb )

7-55

 
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN