REMOVAL
When lifting a motorcycle using a jack, be sure jack con-tacts both lower frame tubes where down tubes and lower frame tubes converge. Never lift by jacking on cross-members, oil pan or other housings. Failure to comply can cause serious damage resulting in the need to perform major repair work. (00586c)
1. Raise the wheel with a suitable lifting device.
2. Inspect the wheel bearings. See2.10 SEALED WHEEL BEARINGS.
3. If present, cut cable straps to release front wheel speed sensor cable and front fender tip lamp wires from left cal-iper brake hose.
4. See Figure 2-2. Remove two brake caliper mounting fasteners (1). Slide brake caliper straight down to remove from brake disc. Secure caliper to rail of engine guard using a cable strap.
5. If necessary, remove retainer (2) to release wheel speed sensor harness from bracket.
6. Remove right side brake caliper.
NOTE
Do not operate the front brake hand lever with the front wheel removed or the caliper pistons may be forced out. The caliper contains no serviceable components and would require replacement.
7. SeeFigure 2-3. Hold the axle stationary with a screwdriver or steel rod through hole in axle (10) on right side and remove the axle nut (1) and flat washer (2).
8. Loosen the two axle holder nuts at bottom of right side fork slider.
1
2
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1. Caliper fasteners
2. Wheel speed sensor cable retainer Figure 2-2. Remove Front Caliper
9. Remove the axle from right side of motorcycle. Catch external spacer(s) and front wheel speed sensor (if ABS equipped) as the axle is removed.
NOTE
If ABS equipped, never pull wheel speed sensor cable taut or use to retain wheel, axle or other components. Always keep wheel speed sensor and ABS encoder bearing away from magnetic fields such as magnetic parts trays, magnetic base dial indicators, alternator rotors, etc. or damage will occur.
10. If necessary, remove five screws (12) to release brake discs from hub.
17
15 16
6 7
8
2 1
3 4 13 11 5
14
9 4 13
3 10 12
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10.
1. Axle nut Axle
2. Flat washer 11. Brake disc (left side)
12.
3. External spacer Screw (10)
4. Standard bearing 13.Brake disc (right side)
14.
5. ABS encoder bearing Laced wheel, chrome
6. Front wheel speed sensor 15.Cast wheel
16.
7. Cable clip Slotted cast wheel
8. Clip bracket 17.Laced wheel, profile
9. Spacer sleeve
Figure 2-3. Front Wheel (Exploded View)
CLEANING AND INSPECTION
1. Thoroughly clean all parts in solvent (wheel speed sensor and bearings excepted) and inspect for damage or excessive wear.
2. Replace brake discs if warped or badly scored. Measure disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc.
2012 Touring Service: Chassis 2-13
INSTALLATION
TORQUE VALUE FASTENER
21.7-32.5 Nm 16-24 ft-lbs
Brake disc (front) screws
81.4-88.1 Nm 60-65 ft-lbs
Front axle nut
14.9-20.3 Nm 132-180
in-lbs Front axle holder nuts
NOTE
When installing front brake discs, align the rivets with the rivets on the opposite disc.
Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c)
1. SeeFigure 2-3. If removed, install brake discs using new screws (12). Tighten screws in a crosswise pattern to 16-24 ft-lbs (21.7-32.5 Nm).
2. Place wheel into position between fork sliders with the valve stem on the right side of the motorcycle.
3. Apply a light coat of ANTI-SEIZE LUBRICANT to axle, bearing bores and bore of spacer sleeve.
4. Slide axle through right fork slider and external spacer into wheel hub.
NOTE
Be sure that grooves on external spacer(s), or index pin on front wheel speed sensor (if ABS equipped), are on the out-board side. If motorcycle is not ABS equipped, external spacers on left and right side of wheel hub are interchangeable.
5. Push axle through front wheel speed sensor (if ABS equipped) or second external spacer, and left fork slider.
6. Install flat washer and axle nut.
7. SeeFigure 2-4. If ABS equipped, rotate front wheel speed sensor in a counter-clockwise direction until index pin makes contact with shoulder on left fork slider.
8. Hold axle stationary and tighten axle nut to 60-65 ft-lbs (81.4-88.1 Nm).
NOTE
When securing the axle holder, equally tighten the nuts so the gaps, front and rear, are approximately the same.
9. Push and hold right fork slider inboard until it contacts external spacer and equally tighten axle holder nuts to 132-180 in-lbs (14.9-20.3 Nm).
NOTE
SeeFigure 2-3. If removed, secure wheel speed sensor cable in bracket (8). Be sure that tab (stamped ABS) on clip is
installed in slot of bracket from inboard side. Clip cannot be installed once mounting fasteners are started.
10. Install left side brake caliper and sensor cable retainer (if equipped). See2.13 FRONT BRAKE CALIPER.
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
11. Operate front brake hand lever several times to set brake pads to proper operating position.
12. If ABS equipped, install three new cable straps as follows:
a. On the brake hose lower crimp capturing front wheel speed sensor cable and brake hose.
b. Approximately midway between the upper and lower brake hose crimps capturing front wheel speed sensor cable, brake hose and front fender tip lamp wires, if equipped.
c. Approximately 2.5 in. (63.5 mm) below the brake hose upper crimp capturing front wheel speed sensor cable, brake hose and front fender tip lamp wires, if equipped.
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Figure 2-4. Front Wheel Speed Sensor Index Pin (ABS Equipped)