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FRONT WHEEL AND BRAKE
CHAS (3^3^)
EAS00517
FRONT WHEEL AND BRAKE
CHASSIS
Order
1
2
3
4
5
6
7
Stop ring
Speedometer cable
Brake adjuster
Front brake cable
Adjusting pin
Wheel axle nut
Wheel axle
8 Collar
9 Front brake shoe plate
10 Front wheel
Job/Part
Removing the front wheel and brake
Remarks
Q’ty
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
1
1
1
1
1 Refer to”REMOVING THE FRONT
1 WHEEL and INSTALLING THE FRONT
1
1
1
1
WHEEL”.
For installation, reverse the removal procedure.
4-1
EAS00518
FRONT WHEEL
FRONT WHEEL AND BRAKE
CHAS (3^3^)
Order Job/Part
Disassembling the front wheel
1 Oil seal
2 Bearing
3 Spacer
4 Bearing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly procedure.
4-2
FRONT BRAKE SHOE PLATE
FRONT WHEEL AND BRAKE
CHAS (3^3^)
Order Job/Part
Disassembling the front brake shoe plate
1 Brake shoe kit
2 Tension spring
3 Camshaft lever
4 Brake shoe wear indicator
5 Return spring
6 Brake camshaft/O-ring
7 Oil seal
8 Oil seal
9 Circlip
0 Plate washer q Speedometer clutch w Speedometer drive gear e Plate washer r Bushing t Oil seal y Speedometer driven gear u Plate washer
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
2
1
1
1
1/1
1 Refer to”DISASSEMBLING THE
1 BRAKE SHOE PLATE” and “ASSEM-
1 BLING THE BRAKE SHOE PLATE”.
1
1
1
1
For assembly, reverse the disassembly procedure.
4-3
FRONT WHEEL AND BRAKE
CHAS (3^3^)
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface. w
Securely support the scooter so that there is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
2. Remove:
8speedometer cable 1
8front brake c a b l e 2
8front wheel axle n u t 3
8front wheel a x l e 4
8collar
8front w h e e l 5
8front brake shoe plate 6
EAS00524
DISASSEMBLING THE BRAKE SHOE PLATE
1. Remove:
8front brake shoe kit
8camshaft lever
8brake shoe wear indicator
8return spring
8brake camshaft
2. Remove:
8circlip
8plate washer
8speedometer clutch
8speedometer drive gear
8plate washer
3. Remove:
8bushing
(with the special tool)
8speedometer driven gear
8plate washer
Meter gear bush tool
90890-01052
NOTE:
Remove the bushing from the brake shoe plate with the meter gear bush tool.
4-4
FRONT WHEEL AND BRAKE
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends -» Replace.
Do not attempt to straighten a bent wheel axle.
2. Check:
• tire
• front wheel
Damage/wear -» Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter
3.
3. Measure:
• radial wheel runout (T)
• lateral wheel runout @
Over the specified limits -» Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm(0.04 in)
4-5
4. Check:
• wheel bearings
Front wheel turns roughly or is loose -»
Replace the wheel bearings.
• oil seal
Damage/wear -» Replace.
5. Replace:
• wheel bearings New
• oil seal New
FRONT WHEEL AND BRAKE
CHAS (3^3^)
• • • • • • • • • • • • • • • • • • • • • • • a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c. Remove the wheel bearings 4 with a general bearing puller3. d. Install the new wheel bearings and oil seal in the reverse order of disassembly.
• • • • • • • • • • • • • • • • • • • • • • •
EAS00535
CHECKING THE SPEEDOMETER GEAR
UNIT
1. Check:
• speedometer clutch
Bends/damage/wear -» Replace.
2. Check:
• speedometer drive gear (T)
• speedometer driven gear ®
Damage/wear -» Replace.
4-6
(If
^
• •
•
B
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FRONT WHEEL AND BRAKE
CHAS (3^3^)
12270603
EAS00536
CHECKING THE BRAKE
The following procedure applies to all of the brake shoes.
1. Check:
• brake shoe lining
Glazed areas -» Repair.
Sand the glazed areas with course sandpaper.
NOTE:
After sanding the glazed areas, clean the brake shoe with a cloth.
2. Measure:
• brake shoe lining thickness a
Out of specification ^Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm (0.08 in) w
Do not allow oil or grease to contact the brake shoes.
NOTE:
Replace the brake shoes as a set, if either is worn to the wear limit.
4-7
3. Measure:
• brake drum inside diameter b
Out of specification ^Replace the wheel.
Brake drum inside diameter limit
(maximum)
110.5 mm (4.35 in)
FRONT WHEEL AND BRAKE
4. Check:
• brake drum inner surface
Oil deposits -» Clean.
Remove the oil with a rag soaked in lacquer thinner or solvent.
Scratches -» Repair.
Lightly and evenly polish the scratches with an emery cloth.
5. Check:
• brake camshaft
Damage/wear -» Replace.
4-8
EAS00537
ASSEMBLING THE BRAKE SHOE PLATE
1. Lubricate:
8brake camshaft
Recommended lubricant
Lithium-soap-based grease
2. Install:
8brake camshaft 1
8spring
8brake shoe wear indicator 2
• • • • • • • • • • • • • • • • • • • • • • • a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft. c. Check that the brake shoes are properly positioned.
• • • • • • • • • • • • • • • • • • • • • • •
V \
) k V~
FRONT WHEEL AND BRAKE
CHAS (3^5^)
3. Install:
8 camshaft lever (T)
X I 8Nm(0.8m
• kg, 5.8ft
• lb)
• • • • • • • • • • • • • • • • • • • • • • • a. Align the camshaft punch mark a and camshaft lever punch mark b is positioned as shown.
• • • • • • • • • • • • • • • • • • • • • • •
4. Install:
8 plate washer
8 speedometer driven gear
8 bushing
(with the special tool)
Meter gear bush tool
90890-01052 y
*JiL k P DBH1
EAS00538
ASSEMBLING THE FRONT WHEEL
1. Install:
8wheel bearing(right)1 New
8spacer
8wheel bearing(left) New
8oil seal New
• • • • • • • • • • • • • • • • • • • • • • • a. Install the new wheel bearings and oil seal in the reverse order of disassembly. c C
Do not contact the wheel bearing inner race
1 or balls 2 . Contact should be made only with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal.
• • • • • • • • • • • • • • • • • • • • • • •
2. Install:
8brake shoe plate
Align the tab on the speedometer clutch with the slot in the wheel hub.
4-9
FRONT WHEEL AND BRAKE
CHAS (3^3^)
EAS00540
INSTALLING THE FRONT WHEEL
1. Lubricate:
8wheel axle
8wheel bearings
8oil seal lips
8speedometer drive gear
8speedometer driven gear
Recommended lubricant
Lithium-soap-based grease
2. Install:
8front w h e e l 1
NOTE:
Make sure the slot ® in the brake shoe plate fits over the stopper ® on the outer tube.
3. Tighten:
8 wheel axle nut
X I 48 Nm (4.8 m * kg, 34.7 ft * lb)
Make sure the brake cable is routed properly. c C
Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
4-10
FRONT WHEEL AND BRAKE
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
8 Adjust the front wheel static balance with the brake disc installed.
1 . Remove:
8balancing weight(s)
4-11
2. Find:
8front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing stand.
• • • • • • • • • • • • • • • • • • • • • • • a. Spin the front wheel. b. When the front wheel stops, put an “X at the bottom of the wheel.
1
” mark c. Turn the front wheel 90° so that the “X
1
” mark d. is positioned as shown.
Release the front wheel. e. When the wheel stops, put an “X
2
” mark at f. the bottom of the wheel.
Repeat steps (d) through (f) several times until all the marks come to rest at the same g. spot.
The spot where all the marks come to rest is the front wheel’s heavy spot “X”.
• • • • • • • • • • • • • • • • • • • • • • •
FRONT WHEEL AND BRAKE
CHAS (3^%
3. Adjust:
8front wheel static balance
• • • • • • • • • • • • • • • • • • • • • • • a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight. b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posid. tion, install a heavier weight.
Repeat steps (b) and (c) until the front wheel is balanced.
• • • • • • • • • • • • • • • • • • • • • • •
4. Check:
8front wheel static balance
• • • • • • • • • • • • • • • • • • • • • • • a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.
• • • • • • • • • • • • • • • • • • • • • • •
4-12
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