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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Telescopic fork maintenance *
The telescopic fork must be serviced at least once a year.
To service the fork, proceed as follows:
Prop up the motorcycle under the frame to take the load off the front wheel.
Disassemble the front wheel, remove screw [1] from the brake caliper and
unscrew holding clamp. Measure the projection of the fork legs at the upper
fork stabilizer and make a note of the measurement.
Loosen the clamping screws [2] on the fork stabilizers and pull the fork legs
down out of the fork stabilizers.
– DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN
DISMOUNTED.
– MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE
WHEEL, OTHERWISE THE BRAKE DISC CAN BE DAMAGED.
Clamp the fork leg into a vise (use protective jaws) and remove the
plugs [3]. Take the preload spacer and the spring out of the fork tube.
Remove screws [4] at the underside of the slider tubes and pull the fork tubes
out of the slider tubes.
Remove the dust scrabbers [5].
Thoroughly clean all parts and check for wear.
Generously lubricate seals and springs and reassemble the telescopic fork.
Tighten the screws on the bottom of the sliding tubes to 30 Nm.
Fill in fork oil and assemble the fork (see below). Degrease the screws on the
brake caliper and apply Loctite 243. Mount the brake caliper and tighten to
20 Nm. Mount brake line and holding clamp.
Insert fork legs in the fork stabilizers (projection as previously noted) and tighten
clamping screws to 20 Nm (top) and 15 Nm (bottom).
Mount front wheel (see chapter: mounting the front wheel).
THE SCREWS [1] MUST BE SECURED WITH LOCTITE 243.
Changing the telescopic fork oil *
Remove front wheel and fork legs (see above).
Remove plugs, preload spacers and springs.
Drain the fork oil into an appropriate container.
Clean the dust scrabbers.
– It is very important to keep the brake disk free from oil and fatty matters.
Otherwise, the braking effect would be strongly reduced.
– After working on the brake system, always operate the hand brake lever
to apply the brake shoes to the brake disk and have a point of pressure.
Pour 170 cm3 SAE 7.5 fork oil into each fork tube.
Slide the fork tube all the way into the slider tube.
Adjust the air-chamber length [A] to 110 mm (4.5 in) by extracting or adding
fork oil.
Insert springs and pretensioning sleeves into the fork tube.
Check O-rings, grease and mount plugs.
Mount the fork legs, front wheel and brake caliper (see above).
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