9. Rear suspension unit: adjustment, removal and examination

  1. 1 The two-way hydraulically damped suspension unit may be adjusted to three spring load settings, Adjustment is effected by using a C-spanner to rotate the adjusting collar at the top of the unit to the desired setting; the normal setting for solo riding is at the top, and the stiffest setting tor maximum loads is with the collar engaged on the lowest position.
  2. Since the unit is sealed, unless any obvious damage is found such as oil leaks around the damper rod or if the unit's body is dented, the unit can only be checked by assessing its performance.
  3. With the machine standing on its wheels press down on the rear and release sharply; the suspension should compress smoothly and return smoothly to the at rest position. If any signs of jerkiness is noted, or if any undue noises are heard the unit must be renewed. The most effective test, however, is to ride the machine. If it is taken to a person who is familiar with the type, he or she should be able immediately to spot a suspension fault to which the regular rider has become accustomed. If there is any evidence of faulty handling or cornering due to worn rear suspension, the unit must be renewed as soon as possible.
  4. Note: before removing the suspension unit ensure that the swinging arm is supported by a block of wood or similar or by a strong strap passed around the swinging arm and frame tubes. If the swinging arm is secured in approximately its normal werking position, ie not more than 349 mm (13.7 in) below the suspension unit, the risk of damage to the sealing gaiter or to the gearbox housing or swinging arm castings will be avoided. Never allow the swinging arm to drop suddenly and sharply.
  5. With the swinging arm supported, remove the suspension unit bottom mounting nut and top mounting bolt and withdraw the unit. On refitting, ensure that the mounting bolt and nuts are fastened to the specified torque wrench settings and that the unit is installed with the spring adjusting collar at the top.
  6. As stated above, the unit can only be renewed if faulty; repairs are not possible since replacement parts are not available and the unit itself is sealed. The only exception to this are the unit mounting bushes which can be removed using a drawbolt arrangement or a vice and suitably sized socket spanners.
  7. If the unit is to be stored for a long time, always keep it upright, except for K75S models and others with 'S' suspension, where the unit should be stored with the damper rod upwards; in all cases this is to prevent the seals from drying out.

9.5a Suspension unit is installed with spring preload collar uppermost ...

9.5b ... both mountings must be fastened to specified torque wrench settings