6 FORK, TRIPLE CLAMP 2 © Info TThe hydrautic compression damping determines the fork suspension behavior. = Turn adjusting screw @ clockwise all the way. Info TAcjusting screw @ is located atthe top end of the right fork leg and is labeled with OM = Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Standard 2tums Info T Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Info The hydraulic rebound damping determines the fork suspension behavior. = Turn adjusting screw @ clockwise all the way. Info T Agjusting screw @ is located at the top end ofthe lft fork leg and is labeled with REB, = Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Standard 2ums Info TH Turn clockwise to increase damping: turn counterclockwise to reduce damp- ing. Preparatory work wtpaice the motoreycl with ait stand. (F p. 10) Main work = Release bleeder screws @. 7 Ary excess pressure escapes from the intro ofthe fork Tighten the bleeer screws 2 Finishing work Remove the motorcycle from the lift stand. (* p. 10)6 FORK, TRIPLE CLAMP 13 Proparatory work = Raise the motorcycle with a lit stand. (Fp. 10) Main work = Push dust boots @ ofboth fork legs downwards. © Info TH the dust boots should remove dust and coarse dirt particles from the inside {ork tubes. Overtime, dirt can penetrate behind the dust boots. If this dit is, not removed, the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs, = Always keep the brake discs free of oil and grease, and clean them with, brake cleaner when necessary. Clean and oil the dust boots and inner fork tube of both fork legs. Universal oll spray ( p. 153) Press the dust boots back into their normal position. = Remove excess oll. Finishing work = Remove the motorcycle from the lift stand. ( p. 10) ~ Remove screws @. Take off clamp @. = Remove sews @ onthe let fork log. Tak off the fork protector, ~ Remove scres @ on the right fork leg. Takeoff the fork protector. ~ Position the fork protection on the right fork leg. Mount and tighten screws @. Guideline Remaining screws, chassis Me TONm (7-4 IbF FD)6 FORK, TRIPLE CLAMP 14 ~ Postion the fork protection onthe let fork lag. Mount and tighten seus @ Guideline Remaining screws, chaste 0 TON (7a ~ Position the brake tne. Mount clamp @. ~ Mount the serons @. Preparatory work = Raise the motorcycle with a lift stand. (* p. 10) = Remove the front wheel. (** p. 59) Main work = Remove screws @ and take off the clamp. — Remove screws @ and take off the brake caliper. = Hang the brake caliper and the brake line loosely to the side, = Loosen screws @. Remove the left fork leg. Loosen screws @. Remove the right fork leg. Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior, = Following modifications, ride slowly at first to get the feel of the new ride behavior. Main work = Position the fork legs. Info I The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp, Position bleeder screws @ to the front. ~ Tighten serews @. Guideline Screw, top tiple clamp we 20 Nn (14.8 Bo = Tighten screws ©. Guideline Seren, batom tpl clamp we 15 Nm (Lt tf)FORK, TRIPLE CLAMP 15 ~ Postion brake caliper, mount and inten screws @ Guidetine ‘Screw, brake caliper me 20 Nm Toctite® 243 (14.8 Ib ft) Position the broke line, Mount the clamp and serews @. Finishing work = Install the front wheel. (* p. 60) (0a C106" 0 CoRR 201857-01 Condit ‘The fork legs have been removed. = Disassemble the fork legs. (%* p. 15) = Disassemble the piston rod. ( p. 18) = Check the fork legs. ( p. 19) = Change the pilot bushing. (** p. 20) = Assemble the piston rod. (* p. 21) = Assemble the fork legs. (* p. 22) Info ‘The operations are the same on both fork legs. 201533:10 Condition The fork legs have been removed. Determine and note down the current state of the rebound andlor compression damoing @. = Fully open the adjuster for the rebound damping.6 FORK, TRIPLE CLAMP 16 See 20152110 “n> 201535110 Ww 20153610, —— [20153710 = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (114035) (* p. 161) = Loosen screw cap @. Info The screw cap cannot be removed yet. LUnclamp the fork leg and clamp it with the axle clamp. Info TH use soft jaws. Push the outer tube down, Hold screw cap @. Loosen nut @. Remove the screw cap. = Remove the nut. Remove bushing @. Drain the fork cil = Remove ust toot @, = Remove lock ing @. ‘ey info The lock ring has a ground end against which a screwdriver can be posi- tioned, 201599-10, ~ Warm up the outer tbe in ares @ ofthe lover siding bushing Guideline 50°0 122 7) = Jerk the outer fork tube off of the inner tube. Info TL The lower sliding bushing must be pulled out ofits bearing seat.6 FORK, TRIPLE CLAMP ” 20154010 Ay [ a F @e 10 = Remove the upper sling bushing @. Info T Without using a tool, pull the stack apart by hand slightly. Warm up the inner tube atthe upper end Guideline 50 mm (1.97 in) ~ Release sliding bushing support @. Pin nut (1727) ( p. 163) ~ Pull sliding bushing support @ out ofthe inner tube. = Remove the piston rod = Toke off the lower siding bushing @. ~ Take off support ring @. ~ Take ot sea ing @. = Take off lock ring @. = Take off dust boot @. = Drain the fork oil Info Hold the spring while doing ths. = Remove spring @® wih preone spacer6 FORK, TRIPLE CLAMP 18 Proparatory work - Disassemble the fork legs. (* p. 15) Main work = Remove adjusting tube @. ES osc 14610 Right fork leg = Clamp the piston rod into a vise Clamping stand (T14016S) (* p. 161) = Remove nut @ with check valve housing @. Remove check valve housing with check valve ball @. eorss.10 Left fork tog =" Clamp the piston rd into 2 vse - Glaraping stand OAOIES)(™ p. 161) = Remove not @ with check vave housing @. ~ Remove check valve ball @. 0154710 = Remeve piston ring @. é zo1ses10 = Warm up the piston rd in area @. Guideline 50°C Waa 0 = Remove spring holder @. Pin wrench (T103) (* p. 159)6 FORK, TRIPLE CLAMP 19 201850-10, # t. 201552:10, He 201583:10, 201966-10, — Remove spring @ — Remove rebound shim @. = Remove piston @. = Remove compression shim @ ~ Remove serine @ ~ Remove pilot bushing support @. = Remove supporting plate @. Con The fork legs are disessembled, = Check inner tube and the axle clamp for damage. » If there is damage: = Change the inner tube,6 FORK, TRIPLE CLAMP 20 ~ Measure the outside diameter at several locations on the inner tube, Ouiside diameter of the inner tube | 34.975... 35.005 mm (1.37697... 1.37816 in) » If the measured value is less than the specified value: = Change the inner tube. = Measure the run-out of the inner tube, Taner tube run-out 0.20 mm (= 0.0079 in) > Ifthe measured value is greater than the specified value: = Change the inner tube. = Check outer tube for damage. » If there is damage: = Change the outer tube, = Check the surface ofthe sliding bushings. > ithe bronze-coored tyer Q) under slicing layer is visible: = Replace te siding bushings. 20151710, = Check the spring lene, Guideline ‘Spring length with preload spacer(s) 377.5 mm (14.862 in) > Ifthe measured value is greater than the specified value: ~ Reduce the thickness of preload spacers @ >the measure value is ess than the specified value = Increase the thickness of preload spacers @. 20184510 © Info The piston rod must be disassembled,6 FORK, TRIPLE CLAMP a = upport pilot bushing support @ with special too! @ a Touring seve T1200 (p60) Press pilot bushing @ out of the pilot bushing support @ with special tool @ Mounting tool (T140228) (*" p. 161) [201554-10, ~ Press the new pilot bushing @ all the way in with special tool @. Mounting tool (1140228) (* p. 161) = Lubricate the special tool. 8 Fork oil (SAE 4) (4860116651) (* p. 150) Calibrating unit (114021) (* p. 161) Press the special tool through the new pilot bushing. ‘7 The pilot bushing is calibrated 20155610, = Mount supporting plate @ I l ~ Mount pilot bushing suppor @. 201855-11 = Clamp the piston rod into a vise. Clamping stand (1140165) ( p. 161) = Mount spring @. Info TThe two springs forthe shims are identical = Mount compression damping shim @ zousse41 @ | ~ SstePseser pslon @ ensues te sng 12009 sandppe = Clean the piston, = Mount the piston, Guideline view @ Piston from above o O) ere Saar aaa 201558-10,6 FORK, TRIPLE CLAMP 2 Mount rebound shim @. = Mount spring @. zorssot ~ Mount and tighten spring holder @. tina ner WEOTE [ss oT Benen Pin wrench (T103) (* p. 159) = Mount piston ring @. a nist ie ee tpestion check vale ball @ inthe nut of) = unt eneck ae housing QD wth the open sie fing the ball. © nie suger = ie i ies [TN en (13.3 Ibf ft) sow Lette @ | Petonctack sate ba ®. = tourt and tighten nut @H with check vave housing @. = Guitare ors The7S TEN sem ra .... Bechet vate tose must ope tt toto = Mount adjusting ube @. P= if ik 201546-11 © Info T The operations are the same on both fork legs. Preparatory work = Assemble the piston rod. (* p. 21)6 FORK, TRIPLE CLAMP 2 — 8 ame | e 201961-10 2 201842-11 | 201867210, 201562-10, Main work = Position preload spacers @. = Postion sering @. Clamp the inner tube with the axle clamp. ‘Mount the special tool. Protecting sleeve (1726) (" p. 162) = Lubricate and mount dust boot @. Lubricant (TS11) (* p. 152) Info Aways change the dust boot, seal ring, lock ring, and support ring. Mount the dust boot with the sealing lip and spring expander facing down. = Slide on lock ring © ~ Lubvicate and mount sea ing © Lubricant (TST p. 150) Info TH Seating tip facing down, open side facing up. = Push on support rng @. = Remove the special oo = Sand the edges ofthe sliding bushes with 600-gnt sandpaper, and then clean and srease them, Fork oil (SAE 4) (4860116681) (* p. 150) ~ Push onthe lone siding bushing @. = Refil wth fork oi Fork oll per fork] 24010 mi Fork oil (SAE 4) (4860116681) leg (B.110.34 fl.oz] (© p. 150) = Position the piston rod. = Mount and tighten sliding bushing suppot @. Guideline Sliding bushing support [M33x0.75 [100 Nm Loctite® 2701 (73.8 tor ft) Pin nut (1727) (* p. 163)6 FORK, TRIPLE CLAMP be 10 ey 201610:10, 201611-10 20156410 20186510 ~ Mount the upper sisng bushing @ Info TH without using a toot, pull the stack apart by hand slightly. = Slide the outer tube onto the inner tube. ~ Hold the lower sliding bushing @ with the longer section of the special tool. Mounting tool (17248) ( p. 162) = Press the sliding bushing all the way into the outer tube. = Position suppor ring @. = Hold seating @ withthe shorter section of the special tol Mounting tool (17248) (* p. 162) = Press the seal ring and support ring all the way into the outer tube, ~ Mount lok ing @. Info The lock ring must engage audibly. ~ stall dust boot © = Push the outer tube down, = Slide on bushing @D. Mount nut (® and serew all the way down, ~ Mount and tighten screw cap ®. Guidatine M12x0.75 2.5 Nm (1.84 tof FO ‘Screw cap on piston rod Info I The screw cap of the right fork leg is marked with OM. The screw cap of the left fork leg is marked with REB. ~ Hold the screw cap and tighten nut @. Guideline ‘Screw cap, lock nut W12x0.75 25 Nm (18.4 tf fo6 FORK, TRIPLE CLAMP ae 201366-10, 201533:11 2 - 2 200669-01 25 Screw srew cap @ into the outer tude Clamp the fork lg in the area ofthe lower triple clamp. Clamping stand (T1403S) (* p. 161) Tighten the screw cap. Guideline ‘Screw cap on outer tube M3Bx1.25 20m (14.8 tor FD ‘Turn adjusting screw of rebound and compression damping @ clockwise all the way. ‘Turn counterclockwise by the number of clicks corresponding to the fork leg type. Guideline Rebound damping Standard 2tuns Compression damping Standard 2tums Remove the lower triple clamp, (** p. 25) Install the lower triple clamp. (** p. 26) Prey 602665-10 paratory work Raise the motorcycle witha lit stand. (Fp. 10) Remove the front wheel. (* p. 59) Remove the fork legs. (7 p. 14) Dismount the start number plate. (* p. 56) Dismount the front fonder. (Fp. 56) in work Remove fuel tank breather @. Remove nut @. Remove screw @, takeoff top triple clamp withthe handlebar and place it on one side. Info T Protect the motorcycle and its attachments against damage by covering them, Do nat bend the cables and tines. Remove protective rng @. Remove the lower triple clamp with he steering stem. Remove the upper steering head bearing6 FORK, TRIPLE CLAMP 6 (6.18 Instaling the lower tiple clamp Main work = Clean the bearing and sealing elements, check for damage, and grease, High viscosity grease (7 9. 152) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing, = Check whether the top steering head seal @ is corecty positioned. ~ Slide on protective rng @. Position the upper triple clamp with the handlebar. Mount nut @, but do not tighten it yet. [The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp, Position bleeder screws @ to the front. = Tighten screws @. Guideline ‘Screw, battom triple clamp ue 15 Nm (LLL ibe fo = Tighten nut @. Guideline ‘Nut, steering stem M205 TON (7-4 Ff)6 FORK, TRIPLE CLAMP 2 = Mount and tignten screw @ Guideline Screw, tp tiple lamp WE ZO Nm (as rf) = Position the fuel tank breather ~ Tighten screws @. Guideline Screw, tp tiple clamp Me 20 Nm (iasiot eocsri-11 ~ Position brake caliper, mount and tighten screns @. Guideline Screw, brake caliper‘ NB 20Nm Loctite? 243 (14.8 lo te ~ Position the broke line and clamp. Mount and tighten screws @ Finishing work = Check that the wiring harness, cables, and brake and clutch lines can mave freely and are routed correctly. Install the front fender. (& p. 56) = Install the start number plate. (** p. 56) = Install the front wheel. ( p. 60) = Check play of steering head bearing. (* p. 27) — Remove the motorcycle from the lift stand. (€ p. 10) Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. = Adjust the steering head bearing play without delay. © Info tthe bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. Preparatory work = Raise the motorcycle with a lift stand. (#* p. 10) Main work Ss = Move the handlebar to the straight-ahead position. Move the fork legs to and fro in S| 7 eon ft 7 'No play should be noticeable in the steering head bearing, SK LA] * Mitte anata a reat (OQ) ( — Adjust the play of the steering head bearing. (*" p. 28) 400738-116 FORK, TRIPLE CLAMP Finis 28 ‘Move the handleber to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. If click positions are noticeable Adjust the play of the steering head bearing. (€ p. 28) Check the steering head bearing and replace if required, ishing work Remove the motorcycle from the lift stand. (* p. 10) Prey eee Mai aT Oo On paatory work Raise the motorcycle witha litt stand. (# p. 10) in work Remove fuel tank breather @. Loosen screws @ Loosen screw @. Loosen and retighten nut @. Guideline Tut, steering ster M200.5 Using aplastic hammer, tap lightly on the upper triple clamp t Tighten screw ©. Guideline 10.Nm (7.4 tf) 0 avoid strains, Screw, top triple clamp ue 20 Nm (14.8 Ibf fo Tighten screws @. Guideline Screw, top triple clamp ue 20 Nm (14.8 off) Position the fel tank breaner @. ishing work ‘Check play of steering head bearing. (* p. 27) Remove the motorcycle from the lift stand. (#* p. 10)7 HANDLEBAR, CONTROLS 29 7-1 Adjusting basic position of clutch ever = Adjust the basic position of the clutch lever to the size of the rider's hand using adjusting screw © Info T_ Turm the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! = Check the throttle grip for smooth operation. = Move the handieber tothe straght-ahead postion. Move the throttle grip back- wards and forwards to ascertain play @ in the thotte cable €02653:11 Play in gas throttle cable 3... 5mm (0.12... 0.2 in) » Ifthe throttle cable play does not meet specitications: = Adjust the play in the throttle cable. (€ p. 30) Danger 20019211 Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death. = When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. ~ Start the engine and let it idle. Move the handlebar to and fro over the entire steer ing range. The idle speed should not change » Ifthe idle speed changes: Adjust the play in the throttle cable. (* p. 30) Preparatory work — Remove the seat. (** p. 53) = Turn the knurled screw on the fuel tap all the way clockwise, = Dismount the fuel tank. (% p. 53) Main work = Check the routing of the thratle cable. The throttle cable @ must be routed behind the handlebar, behind the coolant hose @ an below the fuel tank bracket @. » Ifthe throttle cable is not routed as specified: = Correct the routing of the throttle cable. Finishing work = Install the fuel tank. (% p. 54) = Mount the seat. (* p. 53)7 HANDLEBAR, CONTROLS 30 7.4 Adjusting the play in the throtle cable Preparatory work = Remove the seat. (* p. 53) ‘Turn the knurled screw on the fuel tap all the way clockwise, Dismount the fuel tank. (7 p. 53) = Check the routing of the throttle cable. (* p. 29), Main work = Move the handlebar tothe straight-anead postion = Push back sleeve @. Ensure thatthe throtte cable sleeve is pushed all the way into barelacjuster @. ~ Loosen nut @. e02693-10 = Turn bare! adjuster @ until throttle cable play @) exists at the bottom throttle cable sleeve Guideline Play in gas throttle cable 3. 5mm (O12... 02) = Tighten nut @. ~ Slide on sleeve @. 400192-11 Finishing work = Install the fuel tank. (F p. 54) = Mount the seat. (€ p. 53) = Check the play in the throttle cable. (* p. 29) On the upper triple clamp, there are 2 holes at a distance of @ to each other. Distance @ between holes | 18 mm (0.59 in) ‘The holes on the handlebar support are placed at a distance of @ from the center. Distance @ between hoes [35 mm 0138) The handlebar suppars can be mourted in cere postions. co1951-10 Warning Danger of accidents Handlebar breakage. = Ifthe handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. ~ Remove the screws @. Take off the handlebar clamps. Remove the handlebar and a3! if-o lay it to one si “ Info e+e HD) rctect he motoreyte and its attachments from damage by covering them, Sp Do not bend the cables and lines. cy ~ Remove the screws @. Remove the handlebar support.7 HANDLEBAR, CONTROLS 31 = Place the tiandlebar support in the required position. Fit and tighten the serens @. Guideline ‘Screw, handlebar support | M10 40 Nm (29.5 ibf ft) Loctite® 243 = Position the handlebar. © Info Take sure cabies and wiring are positioned correctly. ~ Position the handlebar clamps. Fit and evenly tignten the screws @. Guideline Screw, handlebar clamp Me 20 Nm (14.8 tof) Info Take sure the gap width is even.