3.1 Remove the split pin and washer (a) to withdraw pivot pin. Note fitting of spring (b)

alignment will cause handling problems. If misalignment is suspected as the result of an accident, it will be necessary to strip the machine completely so the frame can be thoroughly checked.

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Footrests, brake pedal and gearchange lever - removal and installation

Rider's footrests

Removal

1 Remove the split pin and washer from the footrest pivot pin, then withdraw the pivot pin and remove the footrest, noting the fitting of the return spring (see illustration). The footrest rubbers are secured by two bolts on the underside of the footrest and can be renewed separately.

Installation

2 Installation is the reverse of removal. Apply a small amount of copper-based grease to the pivot pin. Use a new split pin and bend its ends securely.

Frame, suspension and final drive 6«3

3.8 Adjuster (A), brake rod (B), brake arm (C), trunnion (D) and spring (E)

3.9 Disconnect spring (A) from lug (B)

3.10 Footrest bracket attachment points on frame (arrowed)

Passenger footrests

Removal

3. Remove the split pin and washer from the footrest pivot pin, then withdraw the pivot pin and remove the footrest, noting the fitting of two washers on the end of the footrest. The footrest rubbers are a push fit on the footrest and can be renewed separately. Installation

4. Installation is the reverse of removal. Apply a small amount of copper-based grease to the pivot pin. Use a new split pin and bend its ends securely.

Brake pedal - R and T models

Removal

5. Remove the right-hand frame side panel (see Chapter 8).

6. Trace the wiring from the brake light switch and disconnect it at the black 2-pin connector.

7. Remove the silencer mounting nut and bolt (see Chapter 4, Section 13).

8. Unscrew and remove the rear brake rod adjuster nut and disconnect the rod from the brake arm (see illustration). Note the position of the spring. Remove the trunnion from the brake arm, thread it onto the brake rod and screw the adjuster nut onto the rod for safekeeping.

9 Disconnect the brake pedal return spring from the lug on the swingarm (see illustration).

10. Unscrew the footrest bracket bolts and remove the bracket (see illustration).

11. Disconnect the brake light switch spring and the pedal return spring from the lugs on the pedal (sec illustration). Remove the split pin from the clevis pin securing the brake pedal to the brake rod. Remove the clevis pin and separate the rod from the pedal.

12. The pedal pivots on the footrest bracket. Remove the circlip and washer from the pedal pivot and remove the pedal (see illustrations).

13. If necessary, unscrew the cap nut and nut/bolt securing the brake pedal bracket to the footrest bracket and separate them.

Installation

14 Installation is the reverse of removal, noting the following:

1. Apply molybdenum disulphide or copper-based grease to the brake pedal pivot (see illustration).

2. Ensure the circlip is a firm fit in its groove on the brake pedal pivot. Don't forget the washer.

3. Fit a new split pin in the clevis pin and bend the split pin ends securely.

4. Tighten all nuts and bolts to the torque settings specified at the beginning of this Chapter.

e) Reset the brake pedal freeplay and check the operation of the brake light switch. If the pedal stop bolt was disturbed, reset it (Chapter 1).

Brake pedal - V, W, SW, X, SX, Y and SY models

Removal

3.11 Brake light switch spring (A) and pedal return spring (B)

15. Remove the right-hand frame side panel (see Chapter 8).

16. Trace the wiring from the brake light switch and disconnect it at the black 2-pin connector.

17. Remove the silencer mounting nut and bolt (see Chapter 4, Section 13).

18. Ensure the rear brake fluid reservoir cap is secure and unscrew the bolt securing the

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3.12a Remove circlip (A) and washer (B)...

3.12b ... and remove pedal from bracket

3.14 Lubricate pedal pivot before reassembly

6*4 Frame, suspension and final drive

3.18 Remove the brake fluid reservoir from the frame bracket (arrowed)

3.20 Pedal return spring (A) and brake light switch spring (B)