Ducati Scrambler 800 - Service manual > Fork - steering head: front fork

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 preload 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.

See also: