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13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50

13




13



13-0
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50

SERVICE INFORMATION ...................... 13-1 REAR BRAKE.........................................13-3
TROUBLESHOOTING ............................. 13-1 REAR SHOCK ABSORBER...................13-4
REAR WHEEL .......................................... 13-2



SERVICE INFORMATION
GENERAL INSTRUCTIONS
During servicing, keep oil or grease off the brake drum and brake linings.


SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Radial 2.0
Rim runout
Rear wheel Axial 2.0
Rear brake drum I.D 110 111
Rear brake lining thickness 4.0 2.0
Rear shock absorber spring free length 202.5 198


TORQUE VALUES
Rear axle nut 11~13kgf-m
Rear shock absorber upper mount bolt 3.5~4.5kgf-m
Rear shock absorber lower mount bolt 2.4~3.0kgf-m
Exhaust muffler joint lock nut 1.0~1.4kgf-m
Exhaust muffler lock bolt 3.0~3.6kgf-m

Special Tool
Cushion Assemble & Disassemble Tool


TROUBLESHOOTING
Rear wheel wobbling Poor brake performance
Bent rim Brake not adjusted properly
Faulty tire Worn brake linings
Axle not tightened properly Worn brake shoes at cam contacting area
Soft rear shock absorber Worn brake cam
Weak shock absorber spring Worn brake drum
Faulty damper




13-1
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50

REAR WHEEL Rear Axle Nut
REMOVAL
Remove the exhaust muffler. ( 2-5)
Remove the rear axle nut to remove the rear
wheel.




INSPECTION
Measure the rear wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over




Inspect the rear brake drum.
Measure the rear brake drum I.D.
Service Limits: 111mm replace if over




INSTALLATION
Install the rear wheel in the reverse order of
removal.
Tighten the rear axle nut.
Torque: 11.0-13.0kg-m
Install the exhaust muffler.
Torque:
Exhaust muffler joint lock nut: 1.0~1.4kgf-m
Exhaust muffler lock bolt: 3.0~3.6kgf-m
First install and tighten the exhaust
muffler joint lock nuts and then the
exhaust muffler lock bolts.
13-2
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50

REAR BRAKE
BRAKE LINING INSPECTION
Measure the brake lining thickness.
Service Limit: 2.0mm replace if below

Keep oil or grease off the brake linings.




Brake Arm Brake Shoes
REAR BRAKE DISASSEMBLY
Remove the rear brake adjusting nut and
disconnect the rear brake cable.
Remove the rear brake shoes.




Adjusting Nut
Brake Arm Bolt Wear Indicator Plate
Remove the brake arm bolt to remove the
brake arm, wear indicator plate and felt seal.
Remove the brake cam.




Brake Arm Brake Cam
Grease
REAR BRAKE ASSEMBLY
Apply grease to the anchor pin.
Apply grease to the brake cam and install it.
Install the brake shoes.




13-3
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50
Punch Mark Wear Indicator Plate
Apply a small amount of engine oil to the felt
seal and install it to the brake cam.
Install the wear indicator plate and brake arm.

Align the wide groove on the wear
indicator plate with the wide tooth of the
brake cam.
Install and tighten the brake arm bolt.

Align the scribed line on the brake arm
with the punch mark on the brake cam.
Return Spring Brake Arm
Brake Cable Brake Arm
Install the brake arm return spring.
Install the brake arm pin.
Connect the brake cable and install the
adjusting nut.
Install the rear wheel. ( 13-2)
Adjust the rear brake lever free play.
( 3-8)




Brake Arm Pin Adjusting Nut
Upper Mount Bolt
REAR SHOCK ABSORBER
REMOVAL
Remove the frame body cover. ( 2-3)
Remove the air cleaner case. ( 5-19)

Remove the rear shock absorber upper and
lower mount bolts.
Remove the rear shock absorber.



Rear Shock Absorber Lower Mount Bolt
Rear Shock Absorber Compressor
DISASSEMBLY
Install the rear shock absorber compressor as
the figure shown.

Install the rear shock absorber lower
joint into the rear shock absorber
compressor.

Compress the rear shock absorber spring.
Special
Cushion Assemble & Disassemble Tool

Cushion Assemble & Disassemble Too
13-4
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50
Lock Nut
Loosen the lower joint lock nut.
Remove the lower joint.
Remove the lock nut, rubber and damper.




Spring
INSPECTION
Inspect the damper rod for bending or
damage.
Inspect the damper for oil leaks.
Inspect the damper rubber for deterioration or
damage.




Damper Damper Rod Rubber

Measure the rear shock absorber spring free
length.
Service Limit: 198mm replace if over




ASSEMBLY
Assemble the rear shock absorbers in the
reverse order of disassembly.

Install the shock absorber spring with
loosely wound coils facing down.
Apply locking agent to the lock nut
threads and tighten the lock nut.




13-5
13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION AGILITY 50
Upper Mount Bolt
INSTALLATION
Install the rear shock absorber.
Install the rear shock absorber upper mount
bolt and then the lower mount bolt.
Tighten the bolts.
Torque:
Upper Mount Bolt: 3.5~4.5kgf-m
Lower Mount Bolt: 2.4~3.0kgf-m
Install the air cleaner case. ( 5-15)
Install the frame body cover. ( 2-3)

Lower Mount Bolt




13-6