10.2 -
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
26
27
 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.
Adjusting the steering head bearings
Note
To adjust the steering bearing clearance, follow what is described in Sect. 4 - 3, Adjusting the steering head bearings.
 
If the problems found are not solved, check the wear of steering bearings (5) and (6) and replace them, if necessary, as described in paragraph “Removal of the steering head components” of this section.
Steering angle adjustment
Loosen the nuts (17) and adjuster screws (16) on both sides of the bottom yoke.
Use a 6 to 6.5 mm spacer (A) fitted to the fork outer tube, or use a gauge.
Turn the front forks to the right until the spacer (A) is seated against the frame top tube.
Turn the adjuster screw (16) on the opposite side to bring it into contact with the stop on the steering head.
Apply threadlocker to the thread of nut (17). Hold the adjuster screw (16) firm and tighten the nut (17). Turn the forks to the opposite side: and repeat the process to adjust the other dowel and tighten the relative lock nut.
Once adjusted, set handlebar completely turned right and ensure that the gap between front brake line and lower frame trellis is at least 1 mm. If it is not so, decrease steering angle by working the right-hand adjuster.
Removal of the steering head components
Note
All parts fitted to the top and bottom yokes, including the wiring and control cables, can remain on the motorcycle provided they do not hinder the following operations.
 
Loosen the screws (24) and remove the steering head from the hose clips (27); recover the washers (25).
Note
In the “ABS“ version the hose clip marked with an arrow is not present.
Loosen the screw (3) securing the steering head (2) to the steering head nut (12).
Remove the steering head (2).
With the service tool no. 88713.1058 loosen the nut (12) and unscrew it from the steering shaft.
Slide the sealing ring (8), the inner race (A) and the ball race (B) of the upper bearing (5) off the steering shaft.
Remove the bottom yoke (15) complete with the steering shaft from the frame tube.
Remove the ball race (B) of the lower bearing (6).
The inner race (A) of the lower bearing (6) and the relative sealing ring (18) will remain on the steering shaft.
Using a universal puller (see figure) remove the inner race (A) and the spacer (13) from the steering shaft, taking care not to damage the seat.
Important
Once disturbed, the oil seals (8) and (18) and bearings (5) and (6) must not be refitted.
 
Using a suitable drift, remove the outer bearing races (C) from the steering head. Proceed with extreme care to avoid damaging the seats.
Disassembly of the steering head
While holding the nuts (9), unscrew and remove the screws (7), washers (11) and the lower clamp (4) from the steering head.
Unscrew the screws (23) and remove the guide (20).
Recover the washers (22) and the headlight support bracket (21).
Reassembly of the steering head
If the spacers (10) were removed from the steering head, lubricate with silicone spray.
Seat the spacers (10) square in the bores (D) in the steering head, orienting them as shown in the figure.
Important
To drive in the spacers (10), use a drift that bears only on the outer ring (E) while applying a counterforce on zone (F) on the underside of the steering head.
 
On completion of the operation, clean all excess lubricant from the components.
Fit the rubber mountings (19) on the headlight support brackets (21).
Fit the headlight support brackets (21), the guide (20) and the washers (22) with the screws (23).
Tighten the screws (23) to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Locate the lower clamp (4) on the steering head.
Fit the screws (7) complete with the washers (11) in the lower clamp (4).
Insert the washers (11) on the screws (7) and start the nuts (9) in their threads.
Tighten the nuts (9) to a torque of 45 Nm ±5% (Sect.   3 - 3, Frame torque settings) while holding the screws (7).
Refitting the steering head components
Important
The steering head bearings (5) and (6) are identical but in no case may their components be swapped around during reassembly.
 
Clean all contact surfaces and lubricate with the recommended grease.
To fit the outer rings (C) of the bearings (5) and (6) to the steering head, use the service tool no. 88713.1062 and proceed as follows:
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Insert the washer (13), sealing ring (18) (with the rim facing upwards) and inner ring (L) of bottom bearing (6) onto the steering shaft after heating it for about 10 minutes to 120 °C.
Insert the tool code 88713.1072 into the steering pin. Push the inner ring (L) on the sealing ring (18), manually pushing for at least 10-15 seconds.
Lubricate the inner bearing race (L) with the recommended grease.
Fit the ball race (M) on the steering shaft with the smaller diameter of the cage facing upwards and grease the ball race.
Insert the steering shaft in steering head and push it in until it is axially seated.
Fit the bottom yoke assembly to frame.
Grease the ball race (B) and fit it to frame top outer race (C).
Fit the inner ring (A) of the upper bearing (5) to the steering head, with the larger diameter side of the race facing upwards.
Install the sealing ring (8) with the flat side facing upwards.
Grease the nut (12).
Tighten the steering shaft nut (12) by hand until it seats against the sealing ring (8).
Fit service bush no. 88713.1058 to the steering shaft nut (12) and fit the torque wrench to the bush.
Tighten the adjuster ring nut (12) to a torque of 30 Nm ±5% (Sect. 3 - 3, Frame torque settings).
Fit the steering head (2) on the steering head nut (12), aligning the fork leg bores with the corresponding bores on the bottom yoke. Relocate the fork legs as described in Section 7 - 10,.1 Refitting the front forks.
Grease the screw (3).
Tighten the screw (3) on the steering head to a torque of 24 Nm ±5% (Sect. 3 - 3, Frame torque settings).
Refit the hose clips (27) on the steering head, starting the screws (24) in their threads with the washers (25).
Place the hose clips (27) onto the non-rotating tabs (M) and tighten the screws (24) to a torque of 8 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Note
In the “ABS“ version the hose clip marked with an arrow is not present.
 
 
 
H