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12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

12




12




12-0
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

SERVICE INFORMATION .................... 12-1 FRONT BRAKE...................................... 12- 7
TROUBLESHOOTING ........................... 12-2 FRONT SHOCK ABSORBER................ 12-18
STEERING HANDLEBAR..................... 12-3 FRONT FORK......................................... 12-21
FRONT WHEEL...................................... 12-4



SERVICE INFORMATION
GENERAL INSTRUCTIONS
Remove the motorcycle frame covers before removing the front wheel. 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 drum and brake linings.


SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Axle shaft runout 0.2
Radial 2.0
Front wheel rim runout
Axial 2.0
Front brake drum I.D 110(SG20AB) 111(SG20AB)
Front brake lining thickness 4.0(SG20AB) 2.0(SG20AB)
Front shock absorber spring free length 210.9 206.4


TORQUE VALUES
Handlebar bolt 4.5~5.5kgf-m
Steering stem lock nut 6.0~8.0kgf-m
Steering top cone race 0.5~1.3kgf-m
Front shock absorber bolt 3.0kgf-m
Front axle nut 5.0~7.0kgf-m
Brake arm bolt 0.8~1.2kgf-m


SPECIAL TOOLS
Long socket wrench,32mm 8angle




12-1
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50


TROUBLESHOOTING
Hard steering (heavy) Front wheel wobbling
Excessively tightened steering stem top Bent rim
cone race Excessive wheel bearing play
Broken steering balls Bent spoke plate
Insufficient tire pressure Faulty tire
Steers to one side or does not track straight Improperly tightened axle nut
Uneven front shock absorbers Soft front shock absorber
Bent front fork Weak shock springs
Bent front axle or uneven tire Insufficient damper oil
Poor brake performance Front shock absorber noise
Incorrectly adjusted brake Slider bending
Worn brake linings Loose fork fasteners
Contaminated brake lining surface Lack of lubrication
Worn brake shoes at cam contacting area
Worn brake drum
Poorly connected brake arm




12-2
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50


STEERING HANDLEBAR
REMOVAL
Remove the handlebar front and rear covers.
( 2-2)
Remove the two bolts attaching each of the
front and rear brake levers.
Remove the front and rear brake levers.


Bolts Bolts
Screws Throttle Pipe


Remove the two throttle holder screws and
throttle holder.
Disconnect the throttle cable from the throttle
pipe and then remove the throttle pipe from
the handlebar.




Throttle Cable



Remove the handlebar lock nut and bolt to
remove the handlebar.




Nut Bolt
Bolt Orifice


INSTALLATION
Install the handlebar onto the steering stem
by aligning the tab on the handlebar with the
bolt orifice on the steering stem.
Install and tighten the handlebar bolt and lock
nut.
Torque: 4.55.5kgf-m




12-3
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Apply grease to the tip of the throttle pipe. Throttle Cable
Install the throttle pipe and connect the
throttle cable.




Brake Levers

Install the front and rear brake levers in the
reverse order of removal.




Bolts Bolts
Axle Nut

FRONT WHEEL
REMOVAL
Jack the motorcycle front wheel off the
ground.
Remove the speedometer cable set screw and
disconnect the speedometer cable.
Remove the front brake cable.
Remove the front axle nut and pull out the
axle.
Remove the front wheel.
Remove the front brake panel and side collar. Brake Cable Speedometer Cable
Adjusting Nut


INSPECTION
AXLE RUNOUT
Set the axle in V blocks and measure the
runout using a dial gauge.
The actual runout is 1/2 of the total indicator
reading.
Service Limit: 0.2mm replace if over




12-4
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

WHEEL RIM
Check the wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over




Turn the wheel bearings and replace the Play
bearings if they are noisy or have excessive
play.
Play




Axial Radial

Dust Seal
DISASSEMBLY
Remove the dust seal.




12-5
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Bearing Puller
Remove the front wheel bearings and
distance collar.

Special

Bearing Puller




Pilot




ASSEMBLY




Grease




Grease




Pack all bearing cavities with grease.
Drive in the left bearing.
Install the distance collar.
Drive in the right bearing.

Drive in the bearing squarely with the
sealed end facing out.




Outer Driver
Pilot

12-6
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Side Collar
Apply grease to a new dust seal lip and install
the dust seal.
Install the side collar.




Dust Seal
Groove
INSTALLATION
Install the front wheel by aligning the brake
panel groove with the front fork tab.
Insert the axle shaft and tighten the axle nut.
Torque: 4.5kg-m
Connect the speedometer cable and secure it
with the screw.
Install the front brake cable and adjust the
front brake lever free play.


Tab

FRONT BRAKE
Remove the front wheel. ( 12-4)
Remove the front brake panel.
INSPECTION
Measure the brake drum I.D.
Service Limit: 111mm replace if over




Brake Shoe Springs Brake Cam
Measure each brake lining thickness.
Service Limit: 2.00mmmm replace if below

Keep oil or grease off the brake linings.




Brake Linings
12-7
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

DISASSEMBLY
Do not swing the brake arm to expand the
brake shoes.
Remove the brake shoes by removing the
brake shoe springs using a screw driver.
Remove the brake arm and return spring.
Remove the wear indicator plate and felt seal.
Remove the brake cam.
Remove the dust seal and speedometer drive
gear.
Speedometer Drive Gear

Dust Seal



Return Spring


1.0kg-m

Brake Shoe

Brake Cam
Brake Arm
Felt Seal
Wear Indicator Plate

Grease Speedometer Drive Gear
ASSEMBLY
Apply grease to the speedometer drive gear
and then install it into the brake panel.
Apply grease to the dust seal lip and install it
into the brake panel.




Dust Seal
Grease
Apply grease to the anchor pin and brake
cam.
Install the brake cam.




Anchor Pin Brake Cam
12-8
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Wear Indicator Plate Brake Cam
Install the return spring by aligning the spring
hook end with the hole in the brake panel.
Apply a small amount of engine oil to the felt
seal and install it to the brake panel.
Install the wear indicator plate on the brake
cam by aligning the tooth on the plate with
the groove on the brake cam.




Return Spring
Bolt
Install the brake arm on the brake cam by
aligning the punch mark on the brake arm and
the scribed line on the brake cam.
Install and tighten the brake arm bolt.
Torque:0.8~1.2kgf-m




Brake Arm
Brake Shoe Springs
Install the brake shoe springs to the brake
shoes and then install the brake shoes into the
brake panel.

INSTALLATION
Install the brake panel onto the front wheel.
Install the front wheel. ( 12-7)
Adjust the front brake lever free play.




Brake Shoes




12-9
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

HYDRAULIC BRAKE (FRONT BRAKE) Upper Limit
Brake Fluid Replacement/Air Bleeding
Check the brake fluid level on level ground.

When operating the brake lever, the
brake reservoir cap must be tightened
securely to avoid spill of brake fluid.
When servicing the brake system, use
shop towels to cover plastic parts and
coated surfaces to avoid damage
caused by spill of brake fluid.

Lower Limit



Brake Fluid Bleeding Bleed Valve
In order to avoid spill of brake fluid, connect
a transparent hose to the bleed valve.
Warning
Brake fluid spilled on brake pads or
brake disk will reduce the braking
effect. Clean the brake pads and brake
disk with a high quality brake degreaser.
Fully apply the brake lever and then loosen
the brake caliper bleed valve to drain the
brake fluid until there is no air bubbles in the
brake fluid. Then, tighten the bleed valve.
Repeat these steps until the brake system is Front Brake Caliper
free of air.

Brake Fluid Refilling
Add DOT-4 brake fluid to the brake
reservoir.
When bleeding, be careful not to allow
air in the brake reservoir flowing into
the brake system.
When using a brake bleeder, follow
the manufacturer`s instructions.
Never use dirty or unspecified brake
fluid or mix different brake fluids be-
cause it will damage the brake system.
Make sure to bleed air from the brake system.




12-10
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Brake Pad/Disk Replacement Pad Pin


The brake pads must be replaced as a
set to ensure the balance of the brake
disk.

Remove the two bolts attaching the brake
caliper.
Remove the brake caliper.

Remove the brake pad pins to remove the
brake pads.
Front Brake Caliper




Install the brake pads in the reverse order of Brake Pads
removal.
Tighten the brake pad pin bolts.
Torque: 1.52.0kgf-m

Keep grease or oil off the brake pads
to avoid brake failure.
Do not reuse the brake pad pin bolts
that have been removed.



Front Brake Caliper




Brake Disk
Measure the brake disk thickness.
Service Limit: 3.0mm
Measure the brake disk runout.
Service Limit: 0.3mm




12-11
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

BRAKE MASTER CYLINDER Brake Master Cylinder Bolts
Removal
First drain the brake fluid from the hydraulic
brake system.

When servicing the brake system, use
shop towels to cover rubber and
plastic parts and coated surfaces to
avoid being contaminated by brake
fluid.
When removing the brake fluid pipe
bolt, be sure to plug the pipe to avoid
b k fl id l k




Disassembly Snap Ring
Remove the piston rubber cover and snap
ring from the brake master cylinder.




Remove the washer, main piston and spring Main Piston Spring Master Cylinder
from the brake master cylinder.
Clean the inside of the master cylinder and
brake reservoir with brake fluid.




Snap Ring




12-12
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Inspection
Measure the brake master cylinder I.D.
Service Limit: 12.75mm
Inspect the master cylinder for scratch or
crack.




Measure the brake master cylinder piston
O.D.
Service Limit: 12.6mm
Before assembly, inspect the lst and 2nd
rubber cups for wear.




Assembly
Before assembly, apply brake fluid to all
removed parts.
Install the spring together with the 1st rubber
cup.

During assembly, the main piston and
spring must be installed as a unit
without exchange.
When assembling the piston, soak the
cups in brake fluid for a while.
Install the cups with the cup lips
facing the correct direction.

Install the main piston, spring and snap ring.
Install the rubber cover.
Install the brake lever.




12-13
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Disassembly Brake Caliper Seat
Remove the brake caliper seat from the brake
caliper.




Remove the piston from the brake caliper. Compressed Air
If necessary, use compressed air to squeeze
out the piston through the brake fluid inlet
opening and place a shop towel under the
caliper to avoid contamination caused by the
removed piston.
Check the piston cylinder for scratch or wear
and replace if necessary.




Piston Oil Seal
Push the piston oil seal outward to remove it.
Clean the oil seal groove with brake fluid.

Be careful not to damage the piston
surface.




12-14
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Place the brake master cylinder on the
handlebar and install the holder with "up" Bolts Punch Mark
mark facing up. Be sure to align the punch
mark with the holder joint.
First tighten the upper bolt and then tighten
the lower bolt.
Torque: 3.04.0kgf-m




"Up" Mark




Install the brake fluid pipe with the attaching
bolt and two sealing washers.

Install the handlebar covers. ( 12-3)
Fill the brake reservoir with recommended
brake fluid to the upper limit and bleed air
according to the method stated in 12-10.




Brake Caliper Bleed Valve




BRAKE CALIPER (FRONT)
Removal
Remove the brake caliper.
Place a clean container under the brake
caliper and disconnect the brake fluid pipe
from the caliper.

Do not spill brake fluid on any coated
surfaces.


Bolt Bleed Valve




12-15
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Check the piston for scratch or wear.
Measure the piston O.D. with a micrometer.
Service Limit: 26.3mm




Check the caliper cylinder for scratch or wear
and measure the cylinder bore.
Service Limit: 26.45mm




Assembly
Clean all removed parts.
Apply silicon grease to the piston and oil seal.
Lubricate the brake caliper cylinder inside
wall with brake fluid.
Install the brake caliper piston with grooved
side facing out.

Install the piston with its outer end 3
5mm protruding beyond the brake
caliper.
Wipe off excessive brake fluid with a clean
shop towel. Apply silicon grease to the
brake caliper seat pin and caliper inside.
Install the brake caliper seat.



12-16
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Installation
Install the brake caliper and tighten the two
bolts.
Torque: 2.93.5kg-m




Bolts




Connect the brake fluid pipe to the brake
caliper and tighten the fluid pipe bolt.
Torque: 2.53.5kg-m
Fill the brake reservoir with recommended
brake fluid and bleed air from the brake syst
em. ( 12-10)




Bolt




12-17
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Upper Mount Bolts
FRONT SHOCK ABSORBER
REMOVAL
Remove the front wheel. ( 12-4)
Remove the front lower cover. ( 2-2)
Remove the front inner fender.
Remove the front shock absorber upper
mount bolts.
Loosen the lower mount bolts to remove the
front shock absorbers.


Shock Absorber Lower Mount Bolts
Circlip
DISASSEMBLY
Remove the dust boot.
Remove the circlip.




Dust Boot
Set the front shock absorber in a vise.
Remove the damper rod, hex bolt and copper
washer.
Pull out the front shock absorber tube.




Washer/Bolt Front Shock Absorber

Shock Absorber Tube
Set the front shock absorber tube in a vise.
Remove the top nut, shock spring, damper,
and damper spring from the front shock
absorber tube.

When holding the shock absorber tube,
place a shop towel to protect it and do
apply too much force .




12-18
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Measure the front shock absorber spring free
length.
Service Limits: Right : 206.4mm
Left : 206.4mm


ASSEMBLY




Top Nut

Dust Seal


Circlip
Damper

Oil Seal



Damper
Spring




Shock Absorber
Spring
Front Shock
Absorber


Shock
Absorber
Tube




12-19
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50

Install the damper spring onto the damper rod
and then install them into the front shock
absorber tube.
Install the shock absorber spring onto the
front shock absorber tube and tighten the top
nut.

Install the front shock absorber spring
with the closely wound coils facing down.



Shock Absorber Tube
Circlip
Set the front shock absorber in a vise.
Insert the shock absorber tube into the shock
absorber and tighten the hex bolt.
(Apply locking agent to the washer and
install it together with the hex bolt.)
Torque: 3.0kgf-m
Add engine oil into the front shock absorber.
Specified Oil: SS#8
Oil Capacity: 381cc


Dust Boot
Upper Mount Bolts
Install the circlip.
Install the dust boot.




Front Shock Absorber Lower Mount Bolts

INSTALLATION
Install the front shock absorbers onto the
steering stem.
Install and tighten the front shock absorber
upper mount bolts.
Tighten the lower mount bolts.

Align the upper mount bolt hole with the
groove on the front fork.
Install the front wheel. ( 12-7)


12-20
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Long Socket Wrench
FRONT FORK
REMOVAL
Remove the steering handlebar. ( 12-3)
Remove the front wheel. ( 12-4)
Disconnect the speedometer cable.
Remove the steering stem lock nut using long
socket wrench.
Special
Long Socket Wrench,32mm 8Angle

Lock Nut Wrench

Remove the top cone race and remove the
steering stem.

Be careful not to lose the steel balls (26
on top race and 29 on bottom race).
Inspect the ball races and cone races for wear
or damage and replace if necessary.

.


Top Cone Race

BOTTOM CONE RACE REPLACEMENT
Remove the bottom cone race using a chisel.

Be careful not to damage the steering
stem and front fork.
Drive a new bottom cone race into place with
a proper driver.



Bottom Cone Race
Ball Race Remover
BALL RACE REPLACEMENT
Drive out the top and bottom ball races.




12-21
12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION AGILITY 50
Driver Handle A
Drive new top and bottom ball races into the
steering head using the outer driver.

Be sure to completely drive in the ball
races.




Outer Driver, 37x40mm

INSTALLATION
Apply grease to the top and bottom ball races
and install 26 steel balls on the top ball race
and 29 steel balls on the bottom ball race.
Apply grease to the ball races and install the
front fork.




Steel Balls
Apply grease to the top cone race and install Top Cone Race
it.
Tighten the top cone race and then turn the
steering stem right and left several times to
make steel balls contact each other closely.

Check that the steering stem rotates
freely without vertical play.




Install the steering stem lock nut and tighten Long Socket Wrench
it while holding the top cone race.
Torque: 6.08.0kgf-m
Install the front wheel. ( 12-7)
Install the steering handlebar. ( 12-3)
Install the speedometer cable. ( 12-7)

Special
Long Socket Wrench,32mm 8Angle


Lock Nut Wrench
12-22