MULTISTRADA 1200 S (ALL COUNTRY VERSIONS)

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Wendy Hardy
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Date: 13/09/2011 Subject: Models: FRONT END KNOCK ON OHLINS FORKS MULTISTRADA 1200 S (ALL COUNTRY VERSIONS) Dear Dealer, We hereby inform you about the technical solution to fix the above-mentioned

1 Date: 13/09/2011 Subject: Models: FRONT END KNOCK ON OHLINS FORKS MULTISTRADA 1200 S (ALL COUNTRY VERSIONS) Dear Dealer, We hereby inform you about the technical solution to fix the above-mentioned fault; noises and vibrations can be perceived at the handlebar when riding on uneven road surface at low speed. On the bikes featuring such fault it is necessary to fit a 0.2 mm shim inside the hydraulic brake control motor unit. The following is the installation procedure: 1. Position the bike on the rear stand. By using the front stand supporting the lower steering plate, make the front wheel lift a few mm from the ground (it is advisable to remove the lower splash guard). Ducati Motor Holding spa Motorcycle Related Products 1/14

Remove the steering plate and lay the handlebar

2 2. Disconnect the fork connectors. NOTE Make sure ignition is SHUT OFF to prevent the suspension ECU from logging unnecessary error codes. Remove the steering plate and lay the handlebar on the tank protecting it by means of a cloth. Ducati Motor Holding spa Motorcycle Related Products 2/14

NOTE Use a plastic bag to protect from the wrench/key the preload adjuster nut. 4.

3 3. Release the spring preload by winding the adjuster counter clockwise (note number of turns, to restore the correct preload at work finished). Use 32mm wrench/key. NOTE Use a plastic bag to protect from the wrench/key the preload adjuster nut. 4. Loosen the 4 screws fastening the fork legs to the steering head, without removing them. 5. By means of tool , fully unscrew both right-hand and left-hand fork upper cap. Ducati Motor Holding spa Motorcycle Related Products 3/14

Use a 32 mm socket wrench and a 19 mm open one to completely

4 6. By working on the front stand, lower the bike so as to let the motor blocks come out of fork sleeves. 7. Use a 32 mm socket wrench and a 19 mm open one to completely release the fork motor block. Ducati Motor Holding spa Motorcycle Related Products 4/14

5 8. Slide the motor block out of the fork leg. 9. Release the rod from its seat by pulling. NOTE Never operate the electric motors when top cap is not installed in the fork. Ducati Motor Holding spa Motorcycle Related Products 5/14

WARNING Be careful because is very easy to cut your skin during this operation.

6 10. Use a 32 mm socket wrench to fully unscrew the motor body until the aluminium bushing is completely released. NOTE Use a plastic bag to protect from the wrench/key the preload adjuster nut. WARNING Be careful because is very easy to cut your skin during this operation. Use a rag or similar or add. 11. Undo the internal nut by means of a 21 mm socket wrench. Ducati Motor Holding spa Motorcycle Related Products 6/14

7 12. Remove the nut, the convex washer and the Teflon one (check the correct positioning of the two washers). 13. Slide the blue electric motor out of its seat by lightly pressing towards the outside to overcome the force of the two O-ring seals. Ducati Motor Holding spa Motorcycle Related Products 7/14

14. Fit a 0.2 mm shim which will place itself on the shim previously set between motor body and blue electric motor. 15. Fit the blue electric motor inside the motor body. 16.

8 14. Fit a 0.2 mm shim which will place itself on the shim previously set between motor body and blue electric motor. 15. Fit the blue electric motor inside the motor body. 16. Reassemble the Teflon washer, the convex one and the nut. Add Loctite 243 or similar to the nut. NOTE Use a plastic bag to protect from the wrench/key the preload adjuster nut. Ducati Motor Holding spa Motorcycle Related Products 8/14

9 Convex washer featuring convex side up. Teflon washer featuring the Teflon side down and the steel one up. 17. Tighten the nut a torque of 25 Nm ± 10%. 18. Reassemble the aluminium bushing in the electric motor body. WARNING Be careful because is very easy to cut your skin during this operation. Use a rag or similar or add. Ducati Motor Holding spa Motorcycle Related Products 9/14

In this case it s necessary to remove the shims (the standard 0,2 and the 0,2 just added, which form together a

10 NOTE If during this operation the preload adjuster nut doesn t move and rotate, means that the 0,2 mm shim just added it s too thick. In this case it s necessary to remove the shims (the standard 0,2 and the 0,2 just added, which form together a total thickness of 0.4 mm) and add a single 0,3 mm shim. 19. Refit the rod in its seat lightly pressing towards the inside, until you feel a distinct snap. Ducati Motor Holding spa Motorcycle Related Products 10/14

20. Turn the nut at the base of the thread, at a distance from the end of the screw at least 27 28 mm,

11 20. Turn the nut at the base of the thread, at a distance from the end of the screw at least mm, according to sketch. 21. Fit the motor body onto the shaft. Ducati Motor Holding spa Motorcycle Related Products 11/14

22. Use a 32 mm socket wrench and a 19 mm open one to fully tighten the screw on the motor body. When the screw is fully home, tighten the check nut as shown in the figure a torque of 20 Nm ± 10%.

12 22. Use a 32 mm socket wrench and a 19 mm open one to fully tighten the screw on the motor body. When the screw is fully home, tighten the check nut as shown in the figure a torque of 20 Nm ± 10%. Make sure shaft reaches bottoms in top cap! 23. By working on the front stand, lift the bike so as to be able to refit the electric motor units in the fork legs. Ducati Motor Holding spa Motorcycle Related Products 12/14

13 24. Add grease to the o-ring. 25. By means of tool tighten again both right-hand and left-hand fork leg upper cap a torque of 20 Nm ± 10%. 26. Tighten again the 4 screws fastening the fork legs to the steering head a torque of 10 Nm ± 5 %. Ducati Motor Holding spa Motorcycle Related Products 13/14

Apply some SHELL Retinax HDX2 grease on screws (3). Refit the U-bolt (4) by starting the screws (3).

14 27. Reset the spring preload. 28. Place the handlebar (1) into its seat onto the stud bolts. The reference points (A) on the handlebar must be equidistant from the stud-bolts and aligned with respect to the stud-bolts plane. Apply some SHELL Retinax HDX2 grease on screws (3). Refit the U-bolt (4) by starting the screws (3). Tighten the screws (3) to 25 Nm ± 5% following the sequence, as indicated. 29. Re-connect the fork connectors (do not mix compression and rebound). Thanks for your attention and best regards, Francesco Penazzo Service After Sales Manager Luca Crucianelli Service Specialist Ducati Motor Holding spa Motorcycle Related Products 14/14

Owners manual. Öhlins Superbike front fork FG 170

Owners manual. Öhlins Superbike front fork FG 170 Owners manual Öhlins Superbike front fork FG 0 Including: Setting up your fork Changing springs and seals Service the fork Trouble shooting Technical info Spare parts & tools Öhlins super bike front fork