Front fork

2 -	Front fork

Screw

3	Steering head

4	Bottom yoke

5	Left fork leg assembly

6	Right fork leg assembly

7	Blanking plug

Washer

Spring

Hose

11	Outer sleeve

12	Complete damper cartridge

13	Adjusting screw

24	Spring guide

Circlip

Cartridge

Spare parts catalogue


Front fork
Handlebar and controls

Caution

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the front fork

Before the front fork can be removed, you will need to remove the components listed below:


Operations	Reference See Section
Remove the front brake calipers	G 3, Removing the front brake system
Removing the front mudguard	E 4, Removing the front mudguard
Removing the front wheel	G 1, Removing the front wheel

Caution

Not all parts covered in this section are available as single spare parts but they are shown for a better understanding of the procedure.

Loosen the pinch bolts (1) holding fork legs to steering head (3).

Loosen the pinch bolts (2) holding fork legs to bottom yoke (4).

Slide the fork legs (5) and (6) out downwards. Overhaul where necessary.

Overhauling the front fork

Note

Loosen the plug (7) on the fork leg when still fitted onto the vehicle.

Note

The special tools required for front fork overhaul are listed in Section C 4, Frame special tools.

Unscrew the cap nut (7).

Disassembling the front fork

Tighten the lock nut (23) with a hexagonal wrench.

Use another hexagonal wrench and loosen plug (7) from cartridge (26), collect gasket (22).

Loosen the lock nut (23), until all thread on cartridge (26) is exposed.

Hold the spring (9) with a hand, collect washer (8) from one side and slowly release spring (9).

Remove the spring (9).

Remove the preload tube (10).

Pump the outer sleeve (11) and the cartridge (26) to let oil off the leg.

Warning

When pumping, oil is pressurised. Aim the fork at a container you will have prepared previously to avoid contact with fork oil.

Clamp the slider (18) in a vice equipped with protection jaws.

Unscrew the compression adjuster (13).

Remove the adjuster screw (13) and collect the seal (14).

Pull out the complete damper cartridge (12).

Remove the dust seal (16) from the outer sleeve (11) with a screwdriver.

Remove the snap ring (17).

Caution

Do not damage the slider (18) and the snap ring (17) housing on the outer sleeve (11).

Pull out the outer sleeve (11) from the slider (18). Quickly tap to counteract the pilot bush (19).

Remove the bush (15) from the slider by inserting a screwdriver into the bush opening.

Remove the following parts from the slider:

Checking the front fork

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

Service limit:

270 mm

Change the spring if not within limit.

Check outer surface of both sliders and inner surface of both outer sleeves. They should show no signs of scores, scratches or distortions.

Check that stanchion tubes are straight.

Maximum straightness error allowed is 0.10 mm.

Each time the slider is separated from the sleeve, it is a good rule to change the pilot bushes (15) and (19).

Check the spring cap (20) for distortion in the highlighted area. Replace, if needed.

Reassembling the front fork

Clamp the slider in a vice.

Tape stanchion tube end to protect it.

Caution

Lubricate sliding surfaces with fork oil or seal grease before fitting the oil seal (21).

When fitting the oil seal (21), its marked surface should point the dust seal (16).

Fit the following parts into the slider (18):

-	dust seal (16);

-	snap ring (17);

-	oil seal (21).

-	spring cap (20);

-	guide bush (19);

-	bush (15).

Note

Lubricate bush sliding surfaces with fork oil before assembling.

Seat the pilot bush (19) and the ring (20) into the outer sleeve (11) with the special tool (F, part no. 88713.1096).

Seat the seal ring (21) into the outer sleeve using the same tool.

Fit the snap ring (17) and the dust seal (16).

Caution

The outer sleeve must slide freely along the slider. Only support the sliders and the outer sleeve with your hands so not to damage the oil seals and the pilot bushes.

Fit the complete damper cartridge (12) into the slider (18).

Fit the seal (14) and the compression adjuster screw (13).

Tighten to 30-40 Nm.

Fill each leg with half the amount of the recommended oil (Sect. C 2, Fuels and lubricants).

Pump up and down to fill whole inner volume.

Take both damper cartridge and outer sleeve to the end of their stroke.

Fill the remaining oil into the leg and measure level.

Caution

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

Recommended oil:

SHELL Advance Fork 7.5 or DONAX TA

Standard capacity:

0.480 cu. dm each leg

Standard oil level:

104 mm

Oil quantity affects fork behaviour when at the end of the compression stroke.

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

Remove oil from the spring (9) and the lock nut (23).

Install the following components:

the preload tube (10), the spring (9)

with the taper side facing the lock nut (23) and the washer (8).

Warning

When refitting the washer (8) compress the spring (9) with a hand.

Tighten the lock nut (23) onto cartridge (26) with a hexagonal wrench.

Use the same wrench to hold the lock nut and tighten the upper plug (7) with O-ring onto the cartridge (26).

Tighten the cap nut (7) to the specified torque (Sect. C 3, Frame torque settings).

Refitting the front fork

Refit the fork legs. Fork leg height above bottom yoke top face is reported in the figure.

Position the fork legs (5) and (6) correctly.

Tighten screws (2) and (1) to the specified torque (Sect. C 3, Frame torque settings) in a 1-2-1 sequence to clamp the fork legs securely in the bottom yoke (4) and steering head (3).

Caution

If the pinch bolts (1) and (2) have been removed on disassembly, smear the threads with the specified grease before tightening.

Warning

Do not ride without the front mudguard, or the brake hoses might contact the wheel under braking.

Refit any components you have removed from the frame:


Operations	Reference See Section
Refitting the front wheel	G 1, Refitting the front wheel
Refitting the front mudguard	E 4, Refitting the front mudguard
Refit the front brake calipers	G 3, Refitting the front brake system