Fork - Steering head: front fork (1200 ABS)

10.1 -

3	Steering head

4	Bottom yoke

5	Left fork leg assembly

6	Right fork leg assembly

7	Counter nut

8	Damper assembly

14	Top cap assembly

Screw

Washer

17	Adjuster screw

18	Special washer

19	Inner tube assembly

Dust cap

21	Sealing ring

Circlip

Bush

24	Outer tube

Bush

Spare parts catalogue


1200 ABS	FRONT FORKS
1200 ABS	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.

Note

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

Refitting the front fork (1200 ABS)

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


Operation	Section reference
Remove the front brake callipers	7 - 3, Removal of the front brake system
Remove the front mudguard	5 - 4, Removal of the front mudguard
Remove the front wheel	7 - 1, Removal of the front wheel
Remove the top fairing	5 -1, Removing the headlight fairing

Loosen the clamp screws (1) holding the fork legs to the steering head (3).

Loosen the clamp screws (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 fork (1200 ABS)

Note

It is advisable to loosen the top cap (14) when the fork is still fitted to the motorcycle.

Note

The specific tools for the revision of the fork, are described in Sect. 3 - 4, Specific tools for the frame.

Loosen the spring preload adjuster before unscrewing the plug (14).

Unscrew the top cap (14) complete with the rebound damping adjuster.

Disassembly of the front fork

Restrain the counter nut (7) with a hex wrench.

Using another hex wrench, unscrew and remove the plug (14), with its seal, from the cartridge (8).

Unscrew the counter nut (7) up to the final threads on the damper (8).

While restraining the spring (10) with one hand, withdraw the bush (9) sideways and then slowly release spring (10).

Slide off the spring (10).

Slide off the preload tube (11) and recover the washer (16).

Drain the oil from inside the leg by pumping with the outer tube (24) and the damper (8).

Warning

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

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

Clamp the inner tube (19) in a vice with soft-faced jaws.

Unscrew the compression damping adjuster (15).

Remove the adjuster screw (15) and recover the seal (13).

Withdraw the damper assembly (8).

Slip the dust seal (20) off the outer tube (24), prising it off with a screwdriver.

Remove the circlip (22).

Important

Take care not to damage the inner tube (19) and the seat of circlip (22) in the outer tube (24).

To separate the outer tube (24) from the inner tube (19), pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush (23).

Insert the tip of a screwdriver in the slit in the bush (25) and open it up sufficiently to slide the bush off the inner tube.

Remove the following parts from the inner fork tube:

-	bush (23);

-	collar (12);

-	sealing ring (21);

-	circlip (22);

-	dust seal (20).

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 allowed error 0.10 mm.

Whenever the inner tube is removed from the sleeve it is good practice to renew the bushes (9) and (23).

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 with tape.

Important

Before installation, smear the sliding edges of sealing ring (21) with fork oil or oil seal grease.

Install the sealing ring (21) with the marked surface facing the dust seal (20).

Fit the following components to the inner tube (19):

-	dust seal (20);

-	circlip (22);

-	sealing ring (21);

-	collar (12);

-	bush (23);

-	bush (25).

Note

Before assembling the inner and outer fork tubes, lubricate the sliding surfaces of the bushes with fork oil.

Push the guide bush (23) and the cap (12) into the external sleeve (24) using the sealing ring tool (F, part no. 88713.3204).

Drive the sealing ring (21) into the outer tube using the same tool.

Fit the circlip (22) and the dust seal (20).

Important

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 sealing rings and the pilot bushes.

Insert the cartridge assembly (8) in the inner tube (19), screwing the tool 88713.3203 onto the cartridge.

Install the gasket (13) and the compression set screw (15) and tighten to the torque (Sect. 3 - 3, Frame torque settings).

Insert half of the prescribed quantity of oil in each fork leg (Sect. 3 - 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:

0.480 dm3 for each fork leg.

Standard oil level:

104 mm.

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.

Clean off any oil from the spring (10) and the counter nut (7) before refitting.

Fit the following components:

the washer (16) and the preload tube (11).

Insert the spring (10), bush (26) and lock nut (7), with the conical side facing lock nut (23) and washer (8).

Screw the counter nut (7) onto the damper (8) with a wrench.

Using the same wrench, restrain the counter nut and screw the top cap (14) complete with the O-ring onto the damper (8).

Tighten the upper plug (14) to the specified torque (Sect. 3 - 3, Frame torque settings).

Refit the front fork (1200 ABS)

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 legs must not exceed 0.1 mm.

Position the fork legs (5) and (6) on the yoke base (4) and on the steering head (3).

Lock the fork legs by tightening the screws (1) to the torque of 10 Nm ± 5% and the screws (2) to the torque of 16 Nm ± 5% (Sect. 3 - 3, Frame torque settings) the retain the bottom yoke (4) and the steering head (3): tighten the screws (2) in the sequence 1-2-1. tighten one fork leg at a time.

Important

If the clamp screws (1) and (2) were 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	5 - 4, Refitting the front mudguard
Refit the front wheel	7 - 1, Refitting the front wheel
Refit the top fairing	5 - 1, Refit the headlight fairing
Refit the front brake callipers	7 - 3, Refitting the front brake system

Warning

Do not ride with the front mudguard removed. The brake hoses are retained to the front mudguard to keep them from touching the wheel under braking.