Front fork

2 -	Front fork

Bolt

Top yoke

4	Bottom yoke

5	Right fork leg assembly

6	Left fork leg assembly

7	Right inner tube assembly

8	Spring kit

15	Outer tube

16	Top cap assembly

17	Left inner tube assembly

Seals kit

19	Overhaul kit

Bolt

Parts catalogue


FRONT FORKS
handlebar and controls

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.

Notes

Not all parts shown are available separately as spares: however they are indicated for clearer explanation of the procedure.

Removal of the front forks

Before removing the front forks, it is first necessary to remove the following parts:


Operation	Section reference
Remove the front brake calipers	G 3, Removal of the front brake system
Remove the front mudguard	E 4, Removal of the front mudguard
Remove the front wheel	G 1, Removal of the front wheel
Remove the headlight fairing	E 1, Removal of the headlight fairing

Loosen the clamp bolts (1) holding the fork legs to the top yoke (3).

Loosen the clamp bolts (2) securing the fork legs to the bottom yoke (4).

Withdraw the fork legs (5) and (6) downwards in order to carry out to all the necessary overhaul operations.

Overhauling the front forks

Notes

It is advisable to loosen the top cap (16) when the fork is still fitted to the motorcycle.

Notes

The service tools required for front fork overhaul are listed in Section C 4, Specific tools for the frame.

Unscrew the top cap (16).

Disassembly of the front fork

Restrain the lock nut (A) with a hex wrench.

Using a second wrench, unscrew and remove the cap (16) with its O-ring seal from the damper.

Withdraw the complete spring kit (8), recovering, in order, the spring (B), the preload tube (C) and the bush.

Drain the oil from inside the leg by pumping with the outer tube (15) and the damper (F).

Warning

This movement generates pressure so that the oil will be rapidly expelled from the fork.

Aim the jet of oil into a previously prepared container and avoid contact with fork oil.

Clamp the inner tube (7) in a vice with soft-faced jaws.

Withdraw the damper assembly (F).

Slip the dust seal (9) off the outer tube (15), prising it off with a screwdriver.

Remove the circlip (10).

Important

Take care not to damage the inner tube (7) and the seat of circlip (10) in the outer tube (15).

Slide the outer tube (15) off the inner tube (7).

From the outer tube, remove:

-	oil seal (11);

-	collar (12);

-	lower bush (13);

-	preload tube (14);

-	top bush (13).

Inspection of the front fork

Place the spring on a flat surface and measure the free length (L).

Service limit:

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:

-	maximum permissible error 0.10 mm.

Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes (13).

Check the collar (12) for distortion in the area indicated. Renew if distorted.

Reassembly of the front fork

Clamp the inner tube in a vice.

Protect the end of the inner tube (7) with tape.

Important

Before installation, smear the sliding edges of oil seal (11) with fork oil or oil seal grease.

Install the oil seal (11) with the marked surface facing the dust seal (9).

Fit the following components to the inner tube (7):

-	dust seal (9);

-	circlip (10);

-	oil seal (11);

-	collar (12).

Install the following components in the outer tube (15) using the oil seal installer no. 88713.3204:

-	bush (13);

-	preload tube (14);

-	bush (13).

Notes

Before assembling the inner and outer fork tube (15), lubricate the sliding surfaces of the bushes (13) with fork oil.

Assemble the inner tube (7) with the outer tube (15).

Push the collar (12) and the oil seal (11) using the oil seal installer no. 88713.3204.

Fit the circlip (10) and the dust seal (9).

Important

The outer tube must slide freely on the inner tube. Handle the inner and outer tubes with your hands only. The use of tools might damage the oil seals and bushes.

Pour half the specified quantity of oil in each fork leg (Sect. C 2, Fuel, lubricants and other fluids).

Pump with tool 88713.3203 to force the oil to fill internal volume completely.

Slide both the damper and outer tube fully down the inner tube.

Pour the remaining oil into the fork leg and measure the oil level.

Important

Keep the fork leg vertical when measuring the oil level. Make sure the oil level is the same in both fork legs.

Recommended oil:

SHELL ADVANCE FORK 7.5 or DONAX TA

Standard capacity:

450 cc (right fork).

470 cc (left fork).

The quantity of oil affects fork response during the final part of the compression stroke.

High oil level increases compression loading, low oil level will decrease it.

Before reassembly, remove any oil from the spring kit (8).

Install the spring kit (8) comprised of, in order, bush (D), preload tube (C) and spring (B), on the inner tube (7).

Restrain lock nut (A) and screw the top cap (16) complete with its O-ring on to the damper rod (8).

Tighten the top cap (16) to the specified torque (Sect. C 3, Frame torque settings).

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.

Warning

The difference in height between the two fork legs must be no greater than 0.1 mm.

Locate the fork legs (5) and (6) in the bottom yoke (4).

Locate the fork legs (5) and (6) in the top yoke (3).

Grease the threads and the undersides of the heads of bolts (1) and (2).

Tighten to the specified torque (Sect. C 3, Frame torque settings) the clamp bolts (1) and (2) securing the legs to the bottom yoke (4) and to the top yoke (3): tighten the bolts (2) in the sequence 1-2-3-1-2.

Important

If the clamp bolts (1) and (2) were fully removed on disassembly, smear the threads with the specified grease before tightening.

Refit any parts removed from the frame:


Operation	Section reference
Refit the front mudguard	E 4, Refitting the front mudguard
Refit the front wheel	G 1, Refitting the front wheel
Refit the headlight fairing	E 1, Refitting the headlight fairing
Refit the front brake calipers	G 3, Refitting the front brake system

Warning

Do not ride the motorcycle without the front mudguard. The front mudguard also acts as a support for the brake hose and prevents the brake hose from touching the wheel when braking.