Page 1
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-0
SUPER 9 50
14
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REAR BRAKE/REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
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SERVICE INFORMATION -------------------------------------------- 14-1
TROUBLESHOOTING ------------------------------------------------- 14-1
REAR BRAKE ----------------------------------------------------------- 14-2
REAR FORK ------------------------------------------------------------- 14-3
REAR WHEEL ---------------------------------------------------------- 14-3
REAR BRAKE DRUM -------------------------------------------------- 14-5
REAR SHOCK ABSORBER-------------------------------------------- 14-7
14
Page 2
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-1
SUPER 9 50
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When performing the services stated in this section, the engine and exhaust muffler must be cold
to avoid scalding.
• During servicing, keep oil or grease off the brake pads and brake disk.
SPECIFICATIONS
Item
Standard (mm)
Service Limit (mm)
Rear wheel rim runout
æ
2.0
Rear shock absorber spring free length
214.7
197.7
Rear brake drum I.D.
110
111
Rear brake disk/ lining thickness
3.5_ 3.8/4.0
3.0/2.0
Rear brake disk runout
æ
0.30
Rear brake master cylinder I.D.
12.700_ 12.743
12.755
Rear brake master cylinder piston O.D.
12.657_ 12.684
12.645
Rear brake caliper cylinder I.D.
33.895_ 33.928
33.860
Rear brake caliper piston O.D.
33.960_ 34.010
34.045
TORQUE VALUES SPECIAL TOOLS
Exhaust muffler lock bolt 29.4_ 39.2N-m Rear shock absorber remover
Rear axle nut 78.4_ 98.0N-m Shock absorber spring compressor
Rear shock absorber lower mount bolt 19.6_ 29.4N-m
Rear shock absorber upper mount bolt 39.2N-m
Rear damper lock nut 14.7_ 24.5N-m
(apply locking agent)
Rear brake caliper bolt 19.6_ 29.4N-m
TROUBLESHOOTING
Rear wheel wobbling Poor brake performance
• Bent rim • Air in brake system
• Faulty tire • Deteriorated brake fluid
• Axle not tightened properly • Contaminated brake pad surface
• Worn brake pads
Soft rear shock absorber • Clogged brake fluid line
• Weak shock absorber spring • Deformed brake disk
• Damper oil leaks • Unevenly worn brake caliper
Rear wheel noise
• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork
Page 3
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-2
SUPER 9 50
REAR BRAKE (SH10DA)
REAR BRAKE CALIPER REMOVAL
First remove the exhaust muffler. (!2-6)
Remove the rear brake fluid tube bolt and
disconnect the brake fluid tube.
Remove the two bolts attaching the rear brake
caliper.
Remove the rear brake caliper.
INSPECTION
Inspect the brake pads and brake disk.
Visually check the brake pad thickness and it
should not exceed the wear indicator mark.
Measure the brake disk thickness.
Service Limit: 3.0mm replace if below
DISASSEMBLY
Disassemble the rear brake caliper. (!14-11)
Inspect and assemble the rear brake caliper .
(!14-12)
Note: The rear brake caliper and front brake
caliper have the same specification.
INSTALLATION
Install the brake caliper to the rear fork and
tighten the two bolts.
Torque: 24.5_ 34.3N-m
Connect the brake fluid tube to the brake
caliper and tighten the fluid tube bolt.
Fill the brake reservoir with the specified
brake fluid and bleed air from the brake
system. (!13-11)
When removing the brake fluid tube, use
shop towels to cover plastic parts and
coated surfaces to avoid damage.
＊
Brake Disk
Fluid Tube Bolt
Brake Pads
Bolts
Copper Washers
Brake Caliper
Wear Indicator Mark
Fluid Tube Bolt
Bolts
When installing the brake fluid tube, be
sure to install the two copper sealing
washers.
＊
Page 4
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-3
SUPER 9 50
REAR FORK (SF10DA)
REMOVAL
Remove the exhaust muffler. (!2-6)
Remove the rear brake caliper. (!14-2)
Remove the rear axle nut and remove the
collar.
Remove the rear fork.
The installation sequence is the reverse of
removal.
Torque:
Rear fork bolt: 19.6_ 29.4N-m
Rear axle nut: 78.4_ 98.0N-m
REAR WHEEL
REMOVAL
Remove the exhaust muffler. (!2-6)
Remove the rear brake caliper. (!14-2)
Remove the rear fork.
Remove the rear axle collar.
Remove the rear wheel.
REMOVAL
Remove the exhaust muffler. (!2-6)
Remove the rear axle nut to remove the rear
wheel.
Collar
Rear Axle Collar
Rear Fork Bolts
Rear Brake Disk
Rear Axle Nut
Page 5
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-4
SUPER 9 50
INSPECTION
Measure the rear wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over
INSTALLATION
The installation sequence is the reverse of
removal.
Torque:
Rear axle nut: 78.4_ 98.0N-m
INSTALLATION
Install the rear wheel and apply SAE30#
engine oil to the axle threads. Then, tighten
the rear axle nut.
Torque values:
Rear axle nut: 107.8_ 127.4N-m
Axle Nut
Brake Caliper Bolts
Rear Axle Nut
Page 6
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-5
SUPER 9 50
REAR BRAKE DRUM
Remove the rear wheel. (!14-3)
Inspect the rear brake drum.
Measure the rear brake drum I.D.
Service Limit: 95.5mm replace if over
BRAKE LINING INSPECTION
Measure the brake lining thickness.
Service Limit: 2.0mm replace if below
REAR BRAKE DISASSEMBLY
Remove the rear brake adjusting nut and
disconnect the rear brake cable.
Remove the rear brake shoes.
Keep oil or grease off the brake linings.
＊
Adjusting Nut
Brake Arm
Brake Shoes
Page 7
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-6
SUPER 9 50
Remove the brake arm bolt to remove the
brake arm, wear indicator plate and felt seal.
Remove the brake cam.
REAR BRAKE ASSEMBLY
Apply grease to the anchor pin and brake
shoe moving parts.
Apply grease to the brake cam and install it.
Apply engine oil to the felt seal and install it
to the brake cam.
Install the wear indicator plate.
Install the brake arm onto the brake cam.
Install and tighten the brake arm bolt.
Install the brake arm return spring.
Install the brake shoes.
Brake Arm Bolt
Wear Indicator Plate
Brake Arm
Brake Cam
Grease
Brake Arm
Wear Indicator Plate
Align the wide tooth of the wear
indicator plate with the wide groove on
the brake cam.
＊
Align the punch mark on the brake arm
with the scribed line on the brake cam.
＊
Page 8
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-7
SUPER 9 50
Install the brake arm pin.
Connect the brake cable and install the
adjusting nut.
Install the rear wheel.
Adjust the rear brake lever free play. (!3-12)
REAR SHOCK ABSORBER
REMOVAL
Remove the rear carrier and frame body cover.
(!2-2)
Remove the met-in box. (!2-2)
Remove the two air cleaner bolts.
Remove the rear shock absorber upper mount
bolt.
Remove the left rear shock absorber upper
and lower mount bolts.
Remove the left rear shock absorbers.
Bolts
Lower Mount Bolts
Air Cleaner
Brake Arm
Adjusting Nut
Brake Arm Pin
Brake Cable
Page 9
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-8
SUPER 9 50
DISASSEMBLY
Disassemble the left rear shock absorbers
using the rear shock absorber remover.
INSPECTION
Inspect the damper rod for bending or
damage.
Inspect the damper for oil leaks.
Inspect the damper rubber for deterioration or
damage.
Measure the front shock absorber spring free
length.
Service Limit:
Left : 226mm
Rear Shock Absorber Remover
Damper
Damper Rod
Rubber
Page 10
14. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
14-9
SUPER 9 50
ASSEMBLY
Assemble the rear shock absorbers in the
reverse order of disassembly.
INSTALLATION
Install the rear shock absorbers in the reverse
order of removal.
Torque:
Upper Mount Bolt: 39.2N-m
Lower Mount Bolt: 19.6_ 29.4N-m
Lower Mount Bolts
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