1 -
Front wheel
1
Nut
2
Valve
3
Right spacer
4
Seal
5
Bearing
6
Front wheel
7
Inner spacer
8
Washer
9
Left spacer
10
Front wheel axle
11
Bolt
 Parts catalogue
FRONT FORKS
FRONT AND REAR WHEELS
 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 wheel
Remove the front brake calipers complete with hoses by undoing the bolts (A).
 Warning
Do not operate the brake lever when the calipers are removed. This could cause fluid to leak out from the actuating pistons.
Support the bike so that the front wheel is raised from the ground.
Loosen and remove the nut (1) on left side of the axle.
Recover the washer (2).
Loosen the axle clamp bolts (11) on the ends of the fork legs.
Working from the left-hand side, use a plastic mallet to drive the axle (10) out from the opposite side and remove it.
Remove the wheel and recover the spacers (3) and (9).
Overhauling the front wheel
Wheel bearings
Before checking the dimensions, check the wear on wheel bearings (5). Check for wear by hand after cleaning and degreasing the bearings in their seats.
Turn the inner race.
Check the amount of radial (A) and axial (B) play. Excessive play will cause vibration and make the bike unstable and therefore the bearings must be renewed.
Position a drift (A) against the inner race of the bearing (5).
Tap the drift with a hammer to drive out the bearing. Apply the drift at different points to keep the bearing square during removal.
 Importante
Once removed, the used bearings and seals must not be refitted.
Before fitting new bearings, check that the housing is clean and free from scoring and damage.
Grease the bearing seat and then push the new bearing (5) into its seat.
Using a tubular drift (D) which bears only on the outer ring of the bearing, drive the bearing fully into its seat.
Use the same method to install the seals (4).
Ensure that spacer (7) is fitted between the two wheel bearings.
 Notes
Wheels must be rebalanced after repair, maintenance and overhaul operations.
Front wheel axle
Check the wheel axle for straightness.
Roll the axle on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Front wheel).
Overhauling the front wheel
After you have checked the bearings, check the rims as follows.
Visually inspect the rim for cracks, scoring and deformation: change the wheel if damaged.
Insert the axle in the wheel and mount it on two fixed reference blocks.
Using a dial gauge, measure rim runout and out-of-round relative to the wheel axle (see Sect. C 1.1, Front wheel).
If the values measured are not within the tolerance limits, renew the wheel.
Refitting the front wheel
When all the necessary inspections have been completed, refit the wheel as follows.
Lubricate and fit the spacers (3) and (9) to the seal rings on the sides of the wheel hub.
Install the complete wheel between the fork legs.
Lubricate the shank and thread of the wheel axle (10).
Fit service tool no. 8000.70139 on the wheel axle (10).
Drive the axle (10) fully home into the wheel hub, inserting the locating peg of the service tool in the special notches at the bottom end of the fork.
Fit the washer (2) on the end of the axle.
Grease the thread and the underside of the head of the axle lock nut (1), then screw it on.
Tighten the nut (1) to the specified torque (Sect. C 3, Frame torque settings).
Refit the front brake calipers complete with hoses securing them with the bolts (A).
 Warning
Do not operate the brake lever when the calipers are removed. This could cause fluid to leak out from the actuating pistons.
Check that the brake discs turn freely inside the calipers.
Before tightening the axle clamp bolts (11), lower the bike to the ground and push up and down on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel axle.
Lubricate the bolts (11).
Tighten the bolts (11) to the specified torque (Sect. C 3, Frame torque settings), in the sequence 1-2-1.
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