Refitting the front fork

Refit fork (5) on bottom yoke (4) by respecting the indicated value.

Lubricate screws (1) and (2) with specified product.

Block the leg by tightening screw (1) to a torque of 24 Nm ± 5%.
Tighten the screws (2) to a torque of 24 Nm ± 5%, following a 1-2-1 sequence.
Refit the previously removed components:
Front brake calliper (Refitting the front brake system).
Front wheel (Refitting the front wheel).
Front mudguard (Refitting the front mudguard). (NOT VALID FOR URBAN ENDURO).
Headlight.
Phonic wheel sensor (Replacing the front phonic wheel).

Fit spacers (C) of screws (B).

Fit leg cover (A) by fixing it with screws (B).
Tighten screws (B) to a torque of 5 Nm ± 10%.
The leg cover procedure is the same for all Scrambler customisations.
Overhauling the front fork

Remove the front wheel (Removing the front wheel)

Remove the forks (Removing the front fork).

The two legs are different: the LH one does not have a spring nor the pre-load tube.
To remove it, follow the removal procedure of the RH leg.

REMOVING THE RH LEG

Vice the fork (1) and pay attention to protect the sleeve.

Apply some adhesive tape on the hexagon flat to prevent any damage.
Slacken the top plug (2).
Take the outer sleeve (1) down.

Drain all fluid from the sleeve.

To help draining, move damper rod a few times, then leave sleeve upside-down until fluid has completely
drained.
 Important
Draining all fluid from the fork is very important. because, due to fork construction and design, it is not
possible to measure the air volume from fluid surface to fork edge when filling the fork with fluid.

Set the fork in the vice and clamp the bottom end. Use the suitable protection plates to avoid any damage.
Remove the fork plug (2) and detach it from damper rod assembly.
Remove pre-load tube (3) and spring (4).
Remove dust seal (5) from outer sleeve (1).
Using suitable tools, remove snap ring (6).

Slide out outer sleeve (1) from fork leg (7) by hitting several times to counter-hold the sliding bushing
resistance.
Remove oil seal (8), washer (9) and bushes (10) and (11).

Important
Protect the sleeve with rubber before vicing it to avoid any damage.

REFITTING THE FRONT FORK

Protect bushing seat with some adhesive tape.

Lubricate fork leg with fork oil and install, in this sequence:

- Dust seal (5);

- Snap ring (6);
- Oil seal (8);
- Shim (9);
- Bushing (10).

Note
Pay attention to the direction of installation of oil seal, spring must face outward.

Fit leg (7) into sleeve (1).

Install bushing (10) in its housing.

Fit shim (9) on bushing.
Using a suitable drift, push bushing/shim assembly fully home.
Then, using the same tool, install oil seal (8).
Fit snap ring (6) and dust seal (5).
Remove the adhesive tape previously applied.
Fit the sliding bushing (11) in its housing.

Fit tool (X) part no. 88713.0950.

Fill in.

Quantity of fluid for the RH leg: 427 cc.

Quantity of fluid for the LH leg: 298 cc.
Activate the damper rod a few times.
Fit spring (4).
 Important
The spring must be oriented and positioned with the side featuring the smaller diameter against the pre-
load tube.

Insert the preload tube (3).

Bring plug (1) fully home on lock nut (12).
Tighten plug (2) on lock nut (12).

Tighten plug (1) on the fork sleeve.

Removing the front fork

Support the front side of the vehicle in a suitable way.

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

- Front brake calliper;

- Front mudguard (Removing the front mudguard); (NOT VALID FOR URBAN ENDURO)
- Front wheel (Removing the front wheel);
- Headlight;
- Phonic wheel sensor (Removing the brake disc).

The procedure below refers to one fork but it applies to both forks.

Remove leg cover (A) by loosening screws (B) and recovering spacers (C).

The leg cover procedure is the same for all Scrambler customisations.

Loosen screw (1) securing the fork sleeve to the steering head (3).
Loosen screw (2) securing the fork sleeve to the bottom yoke (4).
Slide the fork downwards.
Refitting the steering tube components

Important
The steering tube bearings are identical but in no case may their components be swapped during refitting.

Clean all contact surfaces and lubricate with the recommended grease.
To fit the outer rings (C) of bearings to the steering tube, use tool (B) no. 88713.1062. Proceed as
follows:

- heat the steering tube to 150 °C;

- fit the outer rings (C) (upper and lower) in their seats on the steering tube;
- fit the fixed bush (G, with threaded hole) of the tool into the lower ring;
- fit the other movable bush (H) into the upper end of the tool and drive it fully home against the upper
bearing race;
- tighten the nut (L), and use a wrench to seat the outer rings (C) fully in the steering tube;
- leave the tool fitted until the steering tube has cooled down to ensure that bearings are properly
seated.

Fit spacer (9), dust seal (8) (with the rim facing upwards) and inner ring (7) of the lower bearing onto the
steering shaft after heating it for about 10 minutes to 120 °C.
Insert drift no. 88713.1072. Push the inner ring (7) on dust seal (8), manually pushing for at least 10-
15 seconds.
Lubricate the inner ring (7) with the recommended grease. Fit the ball race (6) on the steering shaft with
the smaller diameter of the cage facing upwards, and grease the ball race.

Fit the bottom yoke assembly to frame.

Fit the internal ring (3), the ball race (4) and the external ring (2).
Position ring nut (1) and tighten it to the specified torque.

Refit the following components on the vehicle:

- Forks (Refitting the front fork);

- Handlebar (Refitting the handlebar);
- Front wheel (Refitting the front wheel).
Removing the steering tube components

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

Front wheel (Removing the front wheel).

Forks (Removing the forks).
Handlebar (Removing the handlebar).

Warning
All parts fitted to the steering head and bottom yoke, including wiring and hoses, can remain on the
motorcycle provided they do not hinder the following operations.

Use tool part no. (A) 88713.1058 to loosen ring nut (1) and remove it from the steering.

Remove seal ring (2), internal ring (3) and the ball race (4).
Remove the bottom yoke (5) complete with the steering shaft from the frame.
Remove the ball race (6).

Use a universal puller to remove the internal ring (C), having care not to damage the seat.
 Important
The removed seals and bearings shall not be reused and must be replaced with similar new components.

Remove dust seal (8) and spacer (9).