PIAGGIO Beverly 300ie - Service manual > Front fork

Removal

Overhaul

• Support the fork in a vice.
• Loosen the two tightening screws of the stem supporting clamp.
• Unscrew the stem closing cap and slide off the complete fork leg from the corresponding support.

CAUTION

THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRELOADED.

KEEP THE CAP PROPERLY FITTED DURING THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.

• Support the fork leg properly, remove the main spring and drain off the fork leg oil.

• Remove the hydraulic rod fixing screw with the corresponding sealing gasket:
• With a 19-mm hexagonal spanner, lock hydraulic rod rotation.
• Undo the fixing screw and collect the copper washer.

• Remove the stem dust guard with a screwdriver.

• Remove the circlip retaining the oil seal.

• Take out the stem.

• Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace the damaged parts.

Characteristic

Maximum fork leg diameter
35.10 mm
Minimum stem diameter
34.90 mm

• Take out the oil seal using the appropriate tools.
• Fit the tie rod into the oil seal.
• Insert in sequence the two half-rings per Ø 35- mm stems.

Specific tooling
  020487Y Fork oil seal extractor

• Hold the tie rod manually so that it does not fall into the fork leg and/or that both half-rings are not in their position.
• Fit the bell.
• Tighten the nut until it stops.
• Act on the tool until the oil seal is completely removed.

Specific tooling
  020487Y Fork oil seal extractor

• Remove the hydraulic rod with the corresponding sealing gasket, the spring and the stop bushing.

COMPONENT CHECK

CAUTION

CLEAN ALL THE COMPONENTS THOROUGHLY.

• Check that the fork leg is not cracked or broken in the attachments.
• Check that the stem is not scored, dented or distorted.
• Check that the stop bushing for the hydraulic rod is correctly fixed through caulking.

• Check that hydraulic rod caulkings, the return spring to the unloaded the end of stroke and the hydraulic rod sealing ring are in good conditions.

• Check that the main spring exhibits no signs of yielding or abnormal wear.

• Check that the closing cap O-ring of the stem is in good conditions.

Refitting

• First grease the splitting chamber of the two sealing lips of a new oil seal.
• Fit the sealing ring on the stem and keep the identification words facing upwards.
• Drive the oil seal as far as it will go using the appropriate tool.

Specific tooling
  020376Y Adaptor handle
  020359Y 42x47-mm Adaptor

• Pre-fit the stem with the hydraulic rod, the spring and the stop bushing.
• Fit the pre-assembled components inside the fork leg.

• Fit the hydraulic rod fixing screw with the copper sealing washer and tighten to the prescribed torque using the recommended product.

CAUTION

ALWAYS USE NEW COPPER WASHER.

Locking torques (N*m)
Hydraulic rod fixing screw 25 ÷ 35*

(º) Apply LOCTITE 243 threadlock

• Lock hydraulic rod rotation using a 19-mm hexagonal spanner.

• Fit the oil seal retaining circlip.

• Grease and fit a new dust gaiter.

• Fit the fork leg together with the stem on the fork supporting clamp until it stops.
• Tighten the two screws to the prescribed torque in the sequence indicated in the picture.

Locking torques (N*m)
Stem support clamp tightening screws 20 ÷ 25

• Refill the fork leg with the recommended product to the prescribed amount.

Recommended products
AGIP FORK 7.5 W Oil for fork.

Characteristic

Oil quantity per stem
133 +- 3 cm³

• Bleed the hydraulic rod by actuating the stem repeatedly.
• Fit the spring into the stem.

• Lubricate the closing cap O-ring of the stem.
• Preload the spring, fit the closing cap and tighten to the prescribed torque.

Locking torques (N*m)
Fork locking screws cap 15 ÷ 30

• Repeat the procedure for the other fork leg.

N.B.

IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE RIGHT FORK LEG WITH THE LEFT ONE.

See also: