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RX4 Wheel Removal and Maintenance

RX4 Wheel Removal and Maintenance

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RX4 Wheels Tutorial

General Service Information

  • Keep grease and oil off brake pads and rotors
  • Discard contaminated brake pads and clean rotors with degreaser
  • Brake dust may contain asbestos fibers
  • Do not clean brake dust with compressed air
  • Do not allow water, dirt or other contaminates to enter the hydraulic brake system
  • If brake lever or pedal feels spongy, system needs to be bled.
  • Only use fresh DOT 3 or 4 brake fluid from a sealed container
  • After servicing wheels, brakes or suspension always verify brake function before riding
  • When servicing wheels, suspension or steering, lift motorcycle with suitable work stand
EMISSION RELATED ITEMS
MILES(x)1K 		FIRST SERVICE
500
2.5K
5K
7.5K
10K
12.5
15K
17.5
20K
FUEL LINE * I I I I I
FUEL FILTER * R R R R
THROTTLE OPERATION * I I I I I
AIR CLEANER I I I I
SPARK PLUG I I R I
VALVE CLEARANCE * I I I I
ENGINE OIL R R R R R R R R R
ENGINE OIL FILTER R R R R R R R R R
RADIATOR COOLANT I I R I
COOLING SYSTEM * I I I I
EVAPORATIVE EMISSION CONTROL SYSTEM * I
I I I
NON-EMISSION RELATED ITEMS
MILES(x)1K
FIRST SERVICE
500

2.5K
5K
7.5
10K
12.5
15K
17.5
20K
DRIVE CHAIN I I I I I I I I I
BATTERY I I I I I I I I I
BRAKE FLUID I I I I I R I I
BRAKE PAD WEAR I I I I I I I I
BRAKE SYSTEM I I I I I
BRAKE LIGHT SWITCH * I I I I I
HEADLIGHT AIM * I I I I I
CLUTCH SYSTEM I I I I I
SIDE STAND I I I I I
SUSPENSION * I I I I I
NUTS, BOLTS, FASTENERS I I I I I I I I I
WHEELS/TIRES ** I I I I I I I I I
STEERING HEAD BEARINGS ** I I I I I





Specifications

Standard Torque Values

Bolt Size Torque
5 mm
6 mm
8 mm
10 mm
12 mm 		5.2 mn (3.8 ft lbs)
10 nm (7 ft lbs)
22 nm (16 ft lbs)
34 nm (25 ft lbs)
54 nm (40 ft lbs)


Front Wheel
Rim- 2.15 x 19 in
Tire- 110/80R19,
Cold tire pressure- 36 psi
Wheel runout- 2 mm (0.08 in) Axial/Radial
Axle torque- 106 nm (78 ft lbs)
Axle runout- 0.02 mm (0.008 in)
Spoke nipple size- 6 mm
Spoke nipple torque- 3.7 nm (32.7 in lbs)

Rear wheel
Rim- 4.25 x 17 in
Tire- 150/70R17
Cold tire pressure- 36 psi
Wheel runout- 2 mm (0.08 in) Axial/Radial
Axle torque- 106 nm (78 ft lbs)
Axle runout- 0.02 mm (0.008 in)
Spoke nipple size- 6 mm
Spoke nipple torque- 3.7 nm (32.7 in lbs)
Rear Sprocket- 44 teeth
Chain- 530 x 108 links
Drive chain slack- 25-35 mm (1.0-1.4 in)

Front Fork
Stanchion diameter- 41 mm
Suspension travel- 130 mm (5.1in)
Rebound dampening adjustment- 16 clicks
Fork oil weight- 5w suspension fluid

Rear Shock
Eye to eye length- 44 cm (17.3 in)
Suspension travel- 120 mm (4.7 in)
Rebound dampening adjustment- 6 clicks
Damper gas pressure- 150 psi

Front Brake
Minimum pad thickness- 1 mm (wear indicator)
Minimum rotor thickness- 3 mm
Mounting bolt torque- (22 ft lbs)
Brake fluid- DOT 3 or 4

Rear Brake
Minimum pad thickness- 1 mm (wear indicator)
Minimum rotor thickness- 3 mm
Mounting bolt torque- (22 ft lbs)
Brake fluid- DOT 3 or 4




Troubleshooting

Hard steering

  • Steering stem adjusted to tight
  • Damaged steering head bearings
  • Inadequate lubrication in steering head bearings
  • Low tire pressure

Steers to one side or does not track straight
  • Front wheel installed incorrectly
  • Misaligned rear wheel
  • Loose axle
  • Loose front axle pinch bolts
  • Worn wheel bearings
  • Worn swingarm bearings
  • Bent axle
  • Bent fork tube

Wheels wobble
  • Loose axle
  • Loose front axle pinch bolt
  • Wheels out of balance
  • Faulty tire
  • Bent rim
  • Bent spokes
  • Worn wheel bearings

Brake lever/pedal soft of spongy
  • Air in brake hydraulic system
  • Leak in hydraulic brake system
  • Misadjusted brake lever/pedal
  • Worn seals in master cylinder
  • Worn seals in caliper
  • Clogged passages in brake hydraulic system
  • Low fluid
  • Contaminated brake pads or rotors
  • Warped rotor
  • Bent or worn brake lever/pedal

Wheels

Front Wheel Removal

Step 1: Raise front wheel off the ground using an appropriate work stand

Step 2: Remove brake calipers and let hang

Step 3: Remove axle nut

Step 4: Loosen axle pinch bolts


Step 5: Remove axle and slide out wheel

Step 6: Inspect wheel bearings for smooth operation and excessive play.  Front wheel has identical left and right wheel spacers



Step 7: Lightly grease axle

Step 8: Verify caliper locating dowels are in place. Install caliper



Step 9: When installing front wheel torque

  • Front axle to 106 nm (78 ft lbs)
  • Axle pinch bolt to 20 nm (15 ft lbs)
  • Caliper bolts to 30 nm (22 ft lbs) (use medium strength thread locker)

Step 10: Verify front brake function before riding



Rear Wheel Removal

Step 1 : Raise rear wheel off the ground using an appropriate work stand



Step 2: Remove rear tire hugger

Step 3: Remove axle nut



Step 4: Loosen the drive chain adjuster locknuts and turn the adjustment bolts in several turns

Step 5: Remove axle and adjuster brackets

Step 6: Push wheel forward to derail drive chain from sprocket



Step 7: Remove rear brake caliper and carrier



Step 8: Remove wheel

Step 9: Inspect wheel bearings for smooth operation and excessive play. Rear wheel has corresponding left and right wheel spacers



Step 10: Do not operate rear brake when rear wheel is removed

Step 11: Align rear brake caliper carrier with slot in swingarm



Step 13: Lightly grease axle

Step 14: When installing rear wheel
  • Adjust chain with 25-35 mm of freeplay *see chain adjusted
  • Torque rear axle nut to 106 nm (78 ft lbs)
  • Lightly seat adjuster bolts against adjuster brackets and tighten adjuster locknuts

Step 15: Install rear tire hugger

Step 16: Verify rear brake function before riding