REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

Order

Job/Parts to remove

Q’ty

Remarks

 

Seat

 

Refer to GENERAL CHASSIS.

 

Side cover (left/right)

 

Refer to GENERAL CHASSIS.

 

Shroud (left/right)

 

Refer to GENERAL CHASSIS.

 

Fuel tank

 

Refer to FUEL TANK.

1

Rear shock absorber assembly lower bolt

1

 

2

Rear shock absorber assembly upper bolt

1

 

3

Rear shock absorber assembly

1

 

4

Locknut

1

 

5

Adjusting nut

1

 

Removing the rear shock absorber assembly

Order

Job/Parts to remove

Q’ty

Remarks

6

Lower spring guide

1

 

7

Upper spring guide

1

 

8

Spring

1

 

9

Dust seal

2

 

10

Collar

2

[“a” = 0.3 mm (0.01 in) or more]

11

Bushing

1

 

12

Bearing

1

 

13

Collar

2

 

14

O-ring

2

 

15

Dust seal

2

 

16

Bushing

1

 

17

Stopper ring

1

 

Disassembling the relay arm

Order

Job/Parts to remove

Q’ty

Remarks

1

Relay arm

1

 

2

Connecting arm

1

 

3

Collar

1

 

4

Oil seal

2

 

5

Bearing

2

 

6

Washer

4

 

7

Oil seal

4

 

8

Collar

2

 

9

Washer

4

 

10

Bearing

4

 

HANDLING THE REAR SHOCK ABSORBER

This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.

  • Do not tamper or attempt to open the rear shock absorber.

  • Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure.

  • Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping performance.

A break-in is required up to about 50 km of running.

DISPOSING OF A REAR SHOCK ABSORBER

Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve “1”.

  • Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered.

  • To dispose of a damaged or a worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure.

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY

1.Use a maintenance stand to raise the rear wheel off the ground.

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

2.Remove:

  • Rear shock absorber assembly lower bolt “1”

While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down.

3.Remove:

  • Rear shock absorber assembly upper bolt

  • Rear shock absorber assembly

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY

1.Check:

  • Rear shock absorber rod

    Bends/damage → Replace the rear shock absorber assembly.

  • Rear shock absorber

    Gas leaks/oil leaks → Replace the rear shock absorber assembly.

  • Spring

    Damage/wear → Replace.

  • Spring guide

    Damage/wear → Replace.

  • Bearing

    Damage/wear → Replace.

  • Bolt

    Bends/damage/wear → Replace.

CHECKING THE CONNECTING ARM AND RELAY ARM

1.Check:

  • Connecting arm

  • Relay arm

    Damage/wear → Replace.

2.Check:

  • Bearing

  • Collar

    Damage/pitting/scratches → Replace the bearings and collars as a set.

3.Check:

  • Oil seal

    Damage/pitting → Replace.

INSTALLING THE RELAY ARM

1.Lubricate:

  • Oil seal

  • Bearing

  • Washer

  • Collar

  • Recommended lubricant

    Molybdenum disulfide grease

2.Install:

  • Bearing “1”

  • Washer “2”

  • Oil seal “3”

    (into the relay arm “4”)

  • Collar “5”

  • Installed depth “a”

    0 mm (0 in)

INSTALLING THE CONNECTING ARM

1.Install:

  • Bearing “1”

  • Oil seal “2”

    (into the connecting arm “3”)

  • Collar “4”

  • Installed depth “a”

    0 mm (0 in)

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY

1.Lubricate:

  • Bearing (lower side)

  • Dust seal

  • Recommended lubricant

    Molybdenum disulfide grease

Do not apply the grease to the bearing outer race because it will wear the rear shock absorber surface on which the bearing is press fitted.

2.Lubricate:

  • O-ring

  • Recommended lubricant

    Lithium-soap-based grease

3.Install:

  • Bushing

  • Stopper ring

    (into the rear shock absorber assembly (upper side))

  • Install the bushing parallel until the stopper ring groove appears by pressing its outer race.

  • After installing the stopper ring, push back the bushing until it contacts the stopper ring.

4.Install:

  • Bearing “1”

  • Bushing “2”

  • Collar “3”

  • Dust seal “4”

    (into the rear shock absorber assembly (lower side))

Install the dust seals with their lips facing inward.

  • Installed depth “a”

    0.3 mm (0.01 in) or more

5.Lubricate:

  • Connecting arm and frame bolt

  • Relay arm and connecting arm bolt

  • Relay arm and swingarm bolt

    (circumference and threaded portion)

  • Rear shock absorber assembly upper bolt

  • Rear shock absorber assembly lower bolt

  • Recommended lubricant

    Molybdenum disulfide grease

6.Install:

  • Rear shock absorber assembly

  • When installing the rear shock absorber assembly, lift up the swingarm.

  • Install the rear shock absorber assembly upper bolt, and connecting arm bolt (frame side) from the right.

  • Install the rear shock absorber assembly lower bolts, connecting arm bolt (relay arm side), and relay arm bolt (swingarm side) from the left.

7.Tighten:

  • Rear shock absorber assembly upper nut

  • Rear shock absorber assembly upper nut

    56 N·m (5.6 kgf·m, 41 lb·ft)

  • Connecting arm nut (frame side)

  • Connecting arm nut (frame side)

    80 N·m (8.0 kgf·m, 59 lb·ft)

  • Connecting arm nut (relay arm side)

  • Connecting arm nut (relay arm side)

    80 N·m (8.0 kgf·m, 59 lb·ft)

  • Relay arm nut (swingarm side)

  • Relay arm nut (swingarm side)

    70 N·m (7.0 kgf·m, 52 lb·ft)

  • Rear shock absorber assembly lower nut

  • Rear shock absorber assembly lower nut

    53 N·m (5.3 kgf·m, 39 lb·ft)