12.

STEERING / FRONT WHEEL / FRONT FORK

Mechanism Diagram·················12-1 Front Wheel·······························12-6

Precautions in Operation·········12-2 Front Fork··································12-9
Troubleshooting························12-3 Steering Stem····························12-12
Steering Handlebar···················12-4

Mechanism diagram
6.0~8.0kgf-m

1.0~1.4kgf-m

3.0~3.5kgf-m

0.15~0.25kgf-m

3.0~3.5kgf-m

6.0~8.0kgf-m

3.7~4.3kgf-m

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12. STEERING / FRONT WHEEL / FRONT FORK
Precautions in operation
General information
While removing the front wheel, hold the engine bottom with a hanger to lift the front wheel.
During maintaining, do not stain brake pads with any oil or grease.
The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed
the hydraulic system.
While refilling brake fluid, care should be taken not to let the foreign material entering
the brake system.
Do not spill brake fluid on the painted surfaces, plastic, or rubber parts to avoid damage.
Check the operation of the brake system before riding.
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore,
never use compressed air or dry brush to clean brake system. Use vacuum cleaner or
other authorized tool instead.

Specification measurement：mm
Item Standard Service limit
Wheel axle runout ― 0.2
Axial ― 2.0
Wheel rim runout Radial ― 2.0

Torque value
Front wheel axle locknut 6.0~8.0kgf-m Front brake hose bolt 3.0~4.0kgf-m
Steering handlebar bolt 1.0~1.4kgf-m Air bleed valve 0.8~1.0kgf-m
Steering head thread comp 0.15~0.25kgf-m Brake disk fix bolt 3.7~4.3kgf-m
Steering stem locknut 6.0~8.0kgf-m Front brake caliper bolt 3.5~4.5kgf-m
Front fork bolt 3.0~3.5kgf-m

Special tool
Cone race puller
Steel ball race driver 32×35mm
Steel ball race driver 42×47mm
Inner bearing puller SYM-6204020
Steering stem locknut socket wrench SYM-5320000、SYM-5320010

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12. STEERING / FRONT WHEEL / FRONT FORK
Troubleshooting
Steering mechanism / front fork
Hard steering Worn or damaged front wheel bearing
Steering stem nut too tight
Worn or damaged steering ball bearing
/ seat
Insufficient tire pressure
Soft suspension
Worn fork spring
Steering handlebar tilted Fork seal leakage
Incorrect fork adjustment
Bent forks Hard suspension
Bent wheel axle Bent fork pipes
Damaged tire Excessive fork fluid

Front wheel runout Front suspension noise

Bent wheel rim Bent fork pipes
wheel axle locknut loosened Insufficient fork fluid
Worn tire Loosened suspension

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12. STEERING / FRONT WHEEL / FRONT FORK
Throttle cable locknut
Steering handlebar
Removal
Loosen the throttle cable locknut. Remove the
right handle switch screws. (screw×2)。

screw×2

Remove the throttle cable. Remove the Throttle cable

throttle grip and right handle switch.

Remove the front brake master cylinder. (bolt x2)

bolt×2

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12. STEERING / FRONT WHEEL / FRONT FORK
Remove the left handle switch. (screw x2)

screw×2

locknut
Loosen the clutch cable locknut and
adjusting nut.

Adjusting nut

Remove the clutch lever pivot bolt.

Remove the clutch lever and clutch cable.
Remove the clutch lever socket. (bolt×2)
Remove the handlebar bolts and holders.
(bolt x4) Remove the handlebar.

bolt×2
Installation
Install in the reverse order of removal.
Torque value: Boltx4
Steering handlebar bolt 3.0~3.5kgf-m

Lubricate switches, throttle grip, and

throttle cable when installing.
Align the salient on the switch and the
intaglio on the handlebar holder.
After the handlebar is installed, confirm
and adjust：
throttle grip operation and free play
meter, electrical parts operation
bolt×4

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12. STEERING / FRONT WHEEL / FRONT FORK
axle locknut
Front wheel
Removal
Use a bracket to hold the bottom of engine
and let the front wheel away from the ground.
Remove the front wheel axle locknut.
Pull out the front wheel axle.
Remove the front wheel and side collar.
Caution
Do not pull the front brake lever when
the front wheel is removed to prevent
the brake pads from being pushed out.

Inspection
Wheel axle
Put the axle on a V-block and measure
the run out.
Service limit: 0.2 mm

clearance
Bearing
Rotate the bearings to check if the bearings
rotate smoothly and silently.
clearance
Check if the outer ring of the bearing fixes
firmly on the wheel hub.
Replace the bearing if there is excessive
noise, roughness, or looseness.
Caution
The bearings should be replaced in pair.

Wheel rim
Place the rim in a rotating stand.
Spin the rim by hand and measure the runout
by using a dial indicator.
Service limit: radial 2.0mm
axial 2.0mm

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12. STEERING / FRONT WHEEL / FRONT FORK
Disassembly bolt×5
Remove the brake disk. (bolt×5)。

Pull out the left side bearing and oil seal

by using the inner bearing puller. Remove
the distance collar.
Pull out the right side bearing and oil seal
by using the inner bearing puller.
Special tool
Inner bearing puller SYM-6204020

Assembly
Install in the reverse order of removal.
Bearing will be damaged in these
Apply grease to the wheel hub / bearing contact two examples of assembly.
surface.
Install the left side bearing.
Install the distance collar and the right
side bearing.
Caution
Do not use a used bearing; replace the
bearings in pair when removed from wheel
hub.
The bearing cannot lean to one side
during installation.
Tool：
Bearing driver

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12. STEERING / FRONT WHEEL / FRONT FORK
Installation
Apply grease to the inner and outer side of Oil seal
oil seal and install oil seal into the wheel
hub.

bolt×5
Install brake disk. (bolt×5)。
Torque value: 1.4~1.6kgf-m
Install side collar.

Caution
Contaminated brake pad will decrease
braking efficiency; therefore grease
cannot be applied to brake pad and brake
disk.

Axle locknut
Install the front wheel axle from the right
cushion.
Install the axle locknut and tighten the locknut to
the specified torque.
Torque value: 6.0~8.0kgf-m

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12. STEERING / FRONT WHEEL / FRONT FORK
Speed sensor

Front fork
Disassembly
Remove the front wheel, speed sensor
and front brake caliper.

Remove the front fender. (bolt×6)

3 bolts for both sides

Loosen the front fork bolt on the top bridge.

(bolt×2)

bolt×2
Loosen the front fork bolt on the steering stem.
(bolt×2) Remove the front fork bolt×2

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12. STEERING / FRONT WHEEL / FRONT FORK
Front fork inspection / oil seal
replacement
刮傷
Push the fork pipe for several times to check if
there is any oil leakage or excessive noise.
Check if there is any scratch on the fork pipe if
oil leakage happens.
Replace the front fork if there is a scratch on
the fork pipe.

夾環

If there is oil leakage but without scratch

on the fork pipe, replace the oil seal. Pour
out the fork fluid.
Remove the oil seal stopper ring and
then remove the old oil seal.
Caution
Do not damage the fork pipe
when removing the oil seal.
夾環

油封
Coat the inner side of the new oil seal
with cushion oil and then put in the fork
pipe. Oil seal
Install the oil seal to the right position by using
an oil seal driver.
Clip the stopper ring.

Adjust the fork fluid capacity if the front fork

is too hard or too soft.
Cushion oil : BRAMAX CUSHION OIL
Capacity: 160~180c.c.

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12. STEERING / FRONT WHEEL / FRONT FORK
Installation Fork pipe cap

Caution
The installing will be easier by rotating the
fork pipe.
Install the fork pipe from the bottom of the
front fork. Align the fork pipe cap with the
top bridge.

Top bridge Fork pipe

bolt
Hold the fork pipe by hand and tighten the
front fork upper bolt. (bolt×2)

Tighten the fork bolt on the steering stem.

(bolt×2)
Torque value: 3.0~3.5kgf-m

Tighten the front fork upper bolt. (bolt×2)

bolt
Torque value: 3.0~3.5kgf-m

bolt

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12. STEERING / FRONT WHEEL / FRONT FORK
Steering stem
Removal
Remove the meter, headlight, steering
handlebar, front wheel, front brake and
front fork.
Remove top bridge locknut. (nut×1)

Remove the steering stem locknut and

steering upper cone race by using Top bridge locknut
stem locknut socket wrench.
Special tool:

Stem locknut socket wrench SYM-5320000

Remove the steering stem.
Caution
Keep the steering steel balls in a
container to avoid missing them.

Remove the steering upper ball race steering stem locknut

by rubber hammer.
Remove the steering bottom ball race
by driver.
Remove the steering bottom cone race
from the steering stem.
Caution
Do not damage the frame and
steering stem.

Installation
Install a new steering bottom cone race onto
steering stem locknut
the steering stem and lubricate with grease. Bottom ball race
Install the steering upper / bottom ball race to
Upper cone race
steering stem locknutBottom ball race the right
position. Upper ball race

Caution
Do not let the ball race lean on one side
Upper ball race during installation.
Coat the upper / bottom ball race with
grease and install the steering balls.
Bottom ball rac

12-12
12. STEERING / FRONT WHEEL / FRONT FORK
Install the steering stem into the frame.
Lubricate the steering upper cone race. Tighten steering stem locknut
the upper cone race and steering stem locknut
Counterclockwise
to the steering stem till the steering balls touch 1/2 circle
the upper cone race closely.
Turn the upper cone race counterclockwise 1/2
circle and then tighten it with specific torque
value.
(1/4~3/8 circle)
Clockwise
Special tool: 1/4~3/8
Stem locknut socket wrench SYM-5320000 Steering stem
Top bridge locknut socket SYM-5320010
Torque value: 0.15~0.25kgf-m
Caution
● Do not over tighten upper cone race or
● the steering ball race may be damaged.

Install the top bridge and tighten the nut.

Torque value: 6.0~8.0kgf-m
Caution
● After installation, check if the steering
stem rotate freely without vertical clearance.
Install other parts in the reverse order of removal.
Top bridge locknut

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12. STEERING / FRONT WHEEL / FRONT FORK

NOTE:

12-14