10.1 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
 Spare parts catalogue
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the front forks
Before removing the front forks, it is first necessary to remove the following parts:
 
Important
Not all the components described in this chapter are available as individual replacement parts: however they are indicated for clearer explanation of the procedure.
 
Loosen the clamp screws (25) holding the fork legs to the steering head (23).
Loosen the clamp screws (24) securing the fork legs to the bottom yoke (22).
Withdraw the fork legs (2) and (1) downwards in order to carry out to all the necessary overhaul operations.
Overhauling the front forks
Note
It is advisable to loosen the top cap (7) when the fork leg is still fitted to the motorcycle.
Note
The specific tools for the revision of the fork, are described in Sect. 3 - 4, Specific tools for the frame.
Disassembly of the front fork right leg
Unscrew the top cap (7).
Remove the filler cap assembly (7).
Fit the service tool part no. 88713.0957, engaging its pins (A) in the spring retainer holes, and secure in place with the screw (B).
Push the tool downwards to compress the spring and then fit the tool spacer (C) under the cartridge lock nut (13).
Apply a wrench to the flats (D) and counterhold the lock nut to loosen the top cap (7).
Remove the cap (7).
 
Fit service tool part no. 88713.0958 and screw it onto the damper rod.
Push downwards to overcome the force of the spring and remove the spacer (C).
Remove the service tool part no. 88713.0957 and slide out the preload tube (12).
Remove the spring (9) and pump the outer tube (18) and the damper (8) to expel the oil from the fork leg.
Warning
This movement generates pressure so that the oil will be rapidly expelled from the fork leg.
Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
Clamp the inner tube (6) in a vice with soft-faced jaws.
Unscrew the screw (3).
Remove the adjuster screw (3) and recover the seal (4).
Remove the complete damper assembly (8) and locating ring (10).
Slide the dust seal (E) off the outer tube (18), prising it off with a screwdriver.
Remove the circlip (F).
Important
Take care not to damage the outer tube (18) or inner tube (6).
To separate the outer tube (18) from the inner tube (6), pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush (G).
Insert the tip of a screwdriver in the slit in the bush (H) and open it up sufficiently to slide the bush off the inner tube.
 
Remove the following parts from the inner tube (6):
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Disassembly of the front fork left leg
Unscrew the top cap (7).
Remove the top cap (7) complete with nut (13), rubber bush (15), bush (20), spring and complete damper assembly (17).
Remove the spring (14) and pump the outer tube (18) to expel the oil from the fork leg.
Warning
This movement generates pressure so that the oil will be rapidly expelled from the fork leg.
Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
Slide the dust seal (E) off the outer tube (18), prising it off with a screwdriver.
Remove the circlip (F).
Important
Take care not to damage the outer tube (18) or inner tube (19).
To separate the outer tube (18) from the inner tube (19), pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush (G).
Insert the tip of a screwdriver in the slit in the bush (H) and open it up sufficiently to slide the bush off the inner tube.
 
Remove the following parts from the inner tube (19):
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Inspection of the front fork right leg
Place the spring on a flat surface and measure the free length (L).
Service limit:
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270 mm.
Renew the spring if the length is not within the specified limit.
Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring, steps, or dents.
Check that the outer tubes are straight:
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Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes (G) and (H).
Reassembly of the front fork right leg
Locate the outer tube (18) on the inner tube (6).
Insert the locating bush (10).
Insert the damper assembly (8).
Fit the seal (4) and tighten the adjuster screw (3).
Hold the left fork leg assembly (2) in a vertical position and fill with fork oil, using 500±2,5 CC of the specific oil.
Check the quantity of oil measuring the distance of the level from the end of the outer tube (18).
This distance should be 81 mm.
 
Clean off any oil from spring (9) and spring retainer (12) before assembly.
Note
Install the spring (9), ensuring that the end with tighter coils is towards the bottom of the fork.
 
Fit the following components:
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Fit service tool part no. 88713.0957 (previously used for removal) into the lateral hole of the spring retainer (12).
Press tool down and set spacer (C) under the cartridge (8) lock nut.
Remove service tool no. 88713.0958.
Screw the top cap (7) onto the damper (8).
Using a hexagon wrench, hold the rebound damping adjuster and tighten the top cap to 30 to 40 Nm.
Remove the spacer (C) by pushing the tool part no. 88713.0957 downwards.
Warning
The adjuster on the top cap (7) should be screwed fully onto the thread of the damper (8).
 
Lift the outer tube (18) and tighten the top cap (7) to a torque of 30 to 40 Nm.
Set the adjusters according to riding requirements.
Inspection of the front fork left leg
Place the spring on a flat surface and measure the free length (L).
Service limit:
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270 mm.
Renew the spring if the length is not within the specified limit.
Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring, steps, or dents.
Check that the outer tubes are straight:
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Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes (G) and (H).
Reassembly of the front fork left leg
Locate the outer tube (18) on the inner tube (19).
Before reassembly, remove any oil from the spring (14).
Note
Install the spring (14), ensuring that the end with tighter coils is towards the bottom of the fork.
 
Hold the left fork leg assembly (2) in a vertical position and fill with fork oil, using 538±2.5 CC of the specific oil.
 
Refit the top cap (7) complete with nut (13), rubber bush (15), bush (20), spring and complete damper assembly (17) on the outer tube (18) and tighten to the specified torque.
Refitting the front forks
Refit the fork legs, positioning them at the height shown in the figure relative to the upper surface of the bottom yoke.
Position the legs (2) and (1). If they were removed, grease the thread and the underside of the screws (24) and (25) and place them in their seats.
Tighten the screws (24) to a torque of 24 Nm ±5% and the screws (25) to a torque of 22 Nm ±5% (Sect. 3 - 3, Frame torque settings) in the sequence 1-2-1.
Warning
Do not use the motorcycle without the front mudguard fitted to avoid the risk of the brake pipes fouling the wheel on braking.