user manual

CF front fork assembly
4.1 Disconnect the speedometer cable and the front brake cable.
4.2 Remove the headlight assembly and disconnect the turn signal/horn switch leads and dimmer switch leads.
4.3 Either disconnect the throttle cable from the carburetor or remove the throttle unit from the handlebar or just
be prepared to hang the handlebar from the bike if it is only the forks you are interested in.
4.4 Remove the upper handlebar holders, remove the choke cable stay and remove the handlebars.
4.5 Remove the front wheel (see section 2).
4.6 Remove the front wheel mudguard/fender.
4.7 Remove the front fork bolts from the top yoke/bridge plate.
4.8 Loosen the fork guide caps (Honda recommend a special tool for this: Tool no. 07902 0980000, but you may
be able to find something similar in a good tool shop). and remove the front shock absorber assemblies.
4.9 Remove the top fork bridge/yoke.
4.10 Remove the headlight case.
4.11 Remove the steering top thread and remove the front fork. Do not loose the ball bearings!
4.12 The slide pipe piston has a pin through it. Use an appropriate pin punch and hammer to knock the pin
through. Now the shock absorber can be taken apart.
Examine all the parts for wear and pitting, particularly the numerous bearing faces. Make sure all the cables are
in good condition and operate freely. Examine the electrical connectors for corrosion. Clean all the parts.
Compare the components of one shock absorber with the other as this will be your best guide to something
wrong if you are unsure what to look for when something is wrong. Keep all the parts for each shock absober
assembly separate from the other.
4.13 Clean the ball bearings and their races and re-grease.
4.14 Refit all the balls back in the steering top ball races and fully tighten the steering top thread. Back off the
top thread 1/3 of a turn and check to see that the forks turn with reasonable ease.
4.15 Put the shock absorber assemblies back together, fit the shock absorber gaiters, fork guide cap and fork
pipe guide to the piston first and apply a coat of grease to the shock absorber spring and the fork guide cap.Refit
the slide pipe pistons pins. Make sure that the pin is driven fully home.
4.16 Temporarily fit the top fork bridge.
4.17 Properly install the front shock absorbers with the little indentations on top of the units facing the other
shock absorber. fit the top fork bridge.
4.18 Install the handle bar with the punch marks on the handlebar in line with the lower holders. Fit the upper
holders, remembering to refit the choke mounting strap.
4.19 Refit the front wheel. Connect the brake and speedometer cables at both ends.
4.20 Reconnect the throttle and the wiring connectors.
4.21 Adjust the brakes. check everything is secure.
4.22 Gently road test the bike, make sure everything is secure and readjust the brake if required.
5.0 Rear Wheel & Brake Assembly
5.1 Place some kind of stand under the engine so that the bike sits securely with the rear wheel off the ground.
5.2 Pull out the cotter pin/split pin and remove the axle nut. Slcken the nuts on the axle adjuster on that side and
remove the axle adjuster.
5.3 Remove the brake adjuster nut and disconnect the brake.
5.4 Remove the rear bolt from the rear brake torque arm.
5.5 You may remove the chain by removing the split link. The chain may be left in place,,but when you remove
the wheel you will just have to unhook the chain from the wheel sprocket.
5.6 Slacken the second axle adjuster nuts and remove the axle spindle and the second adjuster.
5.7 Remove the rear wheel and the brake. Do not loose the side collar, which will fall out as the wheel is
removed. To strip the wheel and brake, use the same procedure as for the front wheel (but this brake has no
speedometer drive).