Open the clamp [A].
Clean the ABS hydraulic unit.

NOTICE
Clean all fittings on the ABS hydraulic unit and
the rear master cylinder because dirt around the
banjo bolts could contaminate the brake fluid in
the line during removal/installation. Spread over a
shop towel around the ABS hydraulic unit before
removing the brake line so that brake fluid does
not leak on the parts.

BRAKES 12-57
Anti-Lock Brake System (Equipped Models)

• Remove:
Brake Pipe Banjo Bolts [A]
• Disconnect the brake pipes from the ABS hydraulic unit.
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

the lever [A] backward to disconnect the ABS hy• Pull
draulic unit connector [B].

• Remove:
ABS Hydraulic Unit Bracket Bolts [A]
the ABS hydraulic unit [B] together with the
• Remove
bracket.

• Remove:
ABS Hydraulic Unit Bolts [A] and Washers
Bracket [B]

NOTICE
The ABS hydraulic unit has been adjusted and set
with precision at the factory. Do not try to disassemble and repair the ABS hydraulic unit.

ABS Hydraulic Unit Installation
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

12-58 BRAKES
Anti-Lock Brake System (Equipped Models)
is the reverse of removal.
• Installation
Be
sure
to
install
• bracket [C]. the dampers [A] and collars [B] on the
the washers [D].
• Install
Tighten:
•
Torque - ABS Hydraulic Unit Bolts [E]: 8.8 N·m (0.90 kgf·m,
78 in·lb)
ABS Hydraulic Unit Bracket Bolts [F]: 8.8 N·m
(0.90 kgf·m, 78 in·lb)

the lever [A] forward to connect the ABS hydraulic
• Pull
unit connector [B].
the washers that are on each side of pipe fitting
• Replace
with new one.
the brake pipes (see Cable, Wire, and Hose Rout• Install
ing section in the Appendix chapter).
• Tighten:
Torque - Brake Pipe Banjo Bolts: 33 N·m (3.4 kgf·m, 24 ft·lb)

the brake line (see Brake Line Bleeding).
• Bleed
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.

ABS Hydraulic Unit Inspection

the ABS hydraulic unit (see ABS Hydraulic Unit
• Remove
Removal).
inspect the ABS hydraulic unit.
• Visually
Replace the ABS hydraulic unit if any of them are cracked,
or otherwise damaged.
inspect the connector terminals [A].
• Visually
Replace the ABS hydraulic unit or main harness if either
of the terminals are cracked, bent, or otherwise damaged.
If the ABS hydraulic unit connector is clogged with mud
or dust, blow it off with compressed air.

Front Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get
water or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rotation sensor.

BRAKES 12-59
Anti-Lock Brake System (Equipped Models)
the headlight assy (see Upper Fairing Removal
• Remove
in the Frame chapter).
the front wheel rotation sensor lead connector
• Disconnect
[A].
the front wheel rotation sensor from the bracket
• Remove
[B].
• Clear the sensor lead from the clamp [C].

• Clear the sensor lead from the clamps [A].

• Remove:
Front Wheel Rotation Sensor Bolt [A]
Front Wheel Rotation Sensor [B]

Front Wheel Rotation Sensor Installation
is the reverse of removal.
• Installation
Tighten:
•

Torque - Front Wheel Rotation Sensor Bolt: 6.9 N·m (0.70
kgf·m, 61 in·lb)

the lead correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).

Rear Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get
water or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rotation sensor.

12-60 BRAKES
Anti-Lock Brake System (Equipped Models)

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Remove the connector bracket [A] from the air cleaner
housing.
Remove the rear wheel rotation sensor from the connector bracket.
Disconnect the rear wheel rotation sensor lead connector
[B].
Clear the sensor lead from the clamp [C].

•
•
•
•
the clamps [A].
• Open
• Clear the sensor lead from the clamp [B].

the sensor lead from the clamps [A].
• Clear
• Remove:
Bolt [B]
Clamp

• Clear the sensor lead from the clamps [A].

BRAKES 12-61
Anti-Lock Brake System (Equipped Models)

• Remove:
Rear Wheel Rotation Sensor Bolt [A]
Rear Wheel Rotation Sensor [B]

Rear Wheel Rotation Sensor Installation
is the reverse of removal.
• Installation
• Tighten:

Torque - Rear Wheel Rotation Sensor Bolt: 6.9 N·m (0.70
kgf·m, 61 in·lb)

the lead correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).

Wheel Rotation Sensor Inspection

the front wheel rotation sensor [A] from the front
• Remove
fork.
the rear wheel rotation sensor [B] from the
• Remove
caliper bracket.
inspect the wheel rotation sensors.
• Visually
Replace the wheel rotation sensor if it is cracked, bent, or
otherwise damaged.

12-62 BRAKES
Anti-Lock Brake System (Equipped Models)
Wheel Rotation Sensor Air Gap Inspection

the front/rear wheel off the ground (see Front/Rear
• Raise
Wheel Removal in the Wheels/Tires chapter).
the air gap between the sensor and sensor rotor
• Measure
at several points by turning the wheel slowly.
Thickness Gauge [A]
Air Gap
Standard:
Front

0.2  1.5 mm (0.01  0.06 in.)

Rear

0.2  1.5 mm (0.01  0.06 in.)

NOTE

○The sensor air gap cannot be adjusted.
If the air gap is not within the specification, inspect the hub
bearing (see Hub Bearing Inspection in the Wheels/Tires
chapter), sensor installation condition and sensor (see
Wheel Rotation Sensor Inspection).

Wheel Rotation Sensor Rotor Inspection

inspect the wheel rotation sensor rotor.
• Visually
If the rotor is deformed or damaged (chipped teeth [A]),
replace the sensor rotor with a new one.
If there is iron or other magnetic deposits [B], remove the
deposits.

Fuse Removal

to the Fuse Box Fuse Removal in the Electrical Sys• Refer
tem chapter.

Fuse Installation

fails during operation, inspect the electrical sys• Iftema fuse
to determine the cause, and then replace it with a
new fuse of proper amperage (see Fuse Installation in the
Electrical System chapter).

Fuse Inspection

to the Fuse Inspection in the Electrical System
• Refer
chapter.

SUSPENSION 13-1

Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Rebound Damping Force Adjustment (Left Front Fork Only) ...........................................
Spring Preload Adjustment (Left Front Fork Only)............................................................
Front Fork Removal (Each Fork Leg) ...............................................................................
Front Fork Installation .......................................................................................................
Front Fork Oil Change ......................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube, Outer Tube Inspection ...................................................................................
Dust Seal Inspection .........................................................................................................
Spring Tension Inspection.................................................................................................
Rear Shock Absorber .............................................................................................................
Rebound Damping Force Adjustment...............................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Inspection ......................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
Swingarm Bearing Lubrication ..........................................................................................
Chain Guide Inspection.....................................................................................................
Tie-Rod, Rocker Arm..............................................................................................................
Tie-Rod Removal ..............................................................................................................
Tie-Rod Installation ...........................................................................................................
Rocker Arm Removal........................................................................................................
Rocker Arm Installation.....................................................................................................
Tie-Rod and Rocker Arm Bearing Removal......................................................................
Tie-Rod and Rocker Arm Bearing Installation...................................................................
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection .............................................................
Rocker Arm/Tie-Rod Bearing Lubrication .........................................................................

13-2
13-6
13-7
13-9
13-9
13-9
13-10
13-10
13-10
13-25
13-27
13-28
13-29
13-29
13-30
13-30
13-30
13-30
13-31
13-32
13-32
13-33
13-33
13-33
13-34
13-35
13-36
13-36
13-36
13-37
13-37
13-37
13-38
13-39
13-39
13-40
13-40
13-40

13

13-2 SUSPENSION
Exploded View

SUSPENSION 13-3
Exploded View
No.
1
2
3
4
5
6

Fastener
Front Fork Top Plugs
Upper Front Fork Clamp Bolts
Piston Rod Nut
Lower Front Fork Clamp Bolts
Piston Rod Rubber Nut
Front Fork Bottom Allen Bolt

N·m
22.5
20
15
20.5
15
23

Torque
kgf·m
2.29
2.0
1.5
2.09
1.5
2.3

ft·lb
16.6
15
11
15.1
11
17

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

Remarks

AL
L

13-4 SUSPENSION
Exploded View

SUSPENSION 13-5
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Upper Rear Shock Absorber Bolt
Swingarm Pivot Shaft Nut
Tie-Rod Nuts
Swingarm Pivot Shaft
Swingarm Pivot Shaft Locknut
Rocker Arm Nut
Lower Rear Shock Absorber Nut

G: Apply grease.
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
44
108
44
9.8
98
44
44

Torque
kgf·m
4.5
11.0
4.5
1.0
10
4.5
4.5

ft·lb
32
79.7
32
87 in·lb
72
32
32

Remarks
S
R, S

R, S
R, S

13-6 SUSPENSION
Specifications
Item
Front Fork
Fork Inner Tube Diameter
Air Pressure
Rebound Damper Setting
Fork Spring Preload Setting
Suspension Oil
Amount:
Right Front Fork:
When Changing Oil
After Disassembly and Completely Dry
Left Front Fork:
When Changing Oil
After Disassembly and Completely Dry
Fork Oil Level:
Right Front Fork
Left Front Fork
Fork Spring Free Length
Rear Shock Absorber
Rebound Damper Setting
Spring Preload Setting Position:
Standard
Usable Range
Gas Pressure

Standard
41 mm (1.6 in.)
Atmospheric pressure (non-adjustable)
7 clicks from the fully clockwise position
(Usable Range: 0 ←→ 12 clicks)
8 turns in from the fully counterclockwise position
(Usable Range: 0 ←→ 30 turns in)
Kawasaki KHL15-10 or equivalent

Approx. 440 mL (14.9 US oz.)
515 ±4 mL (17.4 ±0.14 US oz.)
Approx. 370 mL (12.5 US oz.)
434 ±4 mL (14.7 ±0.14 US oz.)
99 ±2 mm (3.9 ±0.08 in.) (fully compressed, without
spring, below from the top of outer tube)
99 ±2 mm (3.9 ±0.08 in.) (fully compressed, without
spring, below from the top of outer tube)
279.9 mm (11.02 in.) (Service Limit: 275 mm (10.8
in.))
1 1/4 turns out from the fully clockwise position
(Usable Range: 0 ←→ 1 4/5 turns out)
Spring length: 199.6 mm (7.86 in.)
Spring length: 190.5  200.5 mm (7.500  7.894 in.)
(stronger to weaker)
1 500 kPa (15.30 kgf/cm², 217.5 psi, Non-adjustable)

SUSPENSION 13-7
Special Tools
Inside Circlip Pliers:
57001-143

Fork Oil Level Gauge:
57001-1290

Oil Seal & Bearing Remover:
57001-1058

Fork Spring Stopper:
57001-1374

Bearing Driver Set:
57001-1129

Hook Wrench T=3.2 R37:
57001-1539

Fork Oil Seal Driver,
57001-1288

41:

Fork Piston Rod Puller, M12 × 1.25:
57001-1289

Fork Spring Compressor:
57001-1540

Fork Spring Compressor:
57001-1587

13-8 SUSPENSION
Special Tools
Needle Bearing Driver,
57001-1609

17/ 18:

Fork Oil Seal Driver Weight,
57001-1795

26  46:

Bar:
57001-1751

Fork Oil Seal Driver Attachment, 36  46:
57001-1798

Fork Spring Compressor:
57001-1771

Swingarm Pivot Nut Wrench:
57001-1872

Fork Piston Rod Stopper Holder:
57001-1789

SUSPENSION 13-9
Front Fork
Rebound Damping Force Adjustment (Left Front
Fork Only)

adjust the rebound damping force, turn the rebound
• To
damping adjuster [A].

○The standard adjuster setting is the 7 clicks from the fully
clockwise position.
○The damping force can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the damping feels too soft or too stiff,
adjust it in accordance with the following table.
Rebound Damping Force Adjustment
Adjuster
Position

Damping
Force