14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/STEERING STEM Downtown 300i ABS
SERVICE INFORMATION
GENERAL INSTRUCTIONS
· Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front
shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to
prevent the motorcycle from falling down.
· During servicing, keep oil or grease off the brake pads and brake disk.
SPECIFICATIONS Unit: mm (in)
Item Standard Service Limit
Axle shaft runout 0.2 mm (0.008 in)
Brake disk thickness 3.8 4.2 (0.15 0.165) 0.3 mm (0.012 in)
Brake disk runout
Brake master cylinder I.D. 12.7 12.74 (0.508 0.5096)
Brake master cylinder piston O.D. 12.65 12.68 (0.506 0.5072)
Brake caliper piston O.D. 26.93 26.96 (1.0602 1.0614)
Brake caliper cylinder I.D. 27 27.05 (1.063 1.065)
TORQUE VALUES
Handlebar lock nut 45 N-m (4.5 kgf-m)
Steering stem lock nut 70 N-m (7.0kgf-m)
Steering stem pinch bolt 27 N-m (2.7 kgf-m)
Front axle 20 N-m (2.0 kgf-m,)
Master cylinder reservoir cover screw 1.6N-m (0.16 kgf-m)
Master cylinder holder bolt 12 N-m (1.2 kgf-m)
Brake lever pivot bolt 2.0 N-m (0.2 kgf-m)
Brake lever pivot nut 10.0 N-m (1.0 kgf-m)
Brake light switch screw 1.0 N-m (0.1 kgf-m)
Brake caliper mounting bolt 35 N-m (3.5 kgf-m)
ALOC bolt: replace with a new one.
Brake caliper bleed screw 5.5N-m (0.55 kgf-m)
Brake hose oil bolt 35 N-m (3.5 kgf-m)
SPECIAL TOOLS
Lock nut wrench F00002
Oil seal and bearing installer E00014
Bearing puller E00037
Lock nut wrench F00023
Ball cone remover F00009
Ball cone installer F00019
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