Derbi servicemanual - Scootergrisen

HUNTER MODELS
Stripping the fork legs
- Withdraw the two screws from the brake caliper.
- Withdraw the front wheel axle nut and slacken
the lock screw.
- Withdraw the front wheel axle, the wheel DIS-
TANCE PIECE, and leave the transfer box and
the separator hanging free.
- Withdraw the fork protection plate screw so as to
be able to extract the external fork leg cap.
- Loosen the 10 x 25 screw from the fork plate and
while pushing upwards on the fork leg, release
the fork bar securing clip.
- Withdraw the fork leg from the vehicle.
Both fork legs are the same.
Stripping the left or right hand fork bar
- Withdraw the safety circlip.
- Undo the fork leg tube cap and seal.
- Drain the hydraulic fluid from the bar.
- Extract the fork leg spring.
- Loosen and extract the fork leg screw.
- Withdraw the hydraulic tube and the bar from the
fork leg.
- Extract the dustguard, the seal securing circlip,
and finally the seal.
Note: Clean thoroughly all the parts which are
to be re-fitted; it is mandatory under all circumstances
to replace the O-rings and seals.
Re-assembly of the fork leg
- Fit the seal into the fork leg size 30-40-7/9. Using
special tool 0.0H.054.0.045.1 and insert the seal
securing circlip.
- Insert the hydraulic tube inside the fork bar.
- Insert the bar inside the fork leg, fit the fork spring
and tighten the 10 x 25 screw using a copper
washer and Loctite to a torque of 35 - 40 Nw x m.
- Re-fill using 80 cc of AGIP FORK SAE10W
hydraulic oil.
8
FRONT FORKS
- Insert the fork leg tube cap with the Oring
seal, the safety circlip and the dustguard.
- Assemble the fork leg into the vehicle.
- Insert the complete fork leg assembly
into the fork plate.
- Fit the safety circlip and the exterior fork
leg cap.
- Tighten the fork plate securing screw.
- Tighten the mudguard/fork plate protector
securing screw.
- Locate the wheel axle, the transfer box,
the transfer box bushing, the wheel, and
fit the brake caliper onto the brake disc;
then the distance piece, the washer, the
spring washer and nut, tightening to a
torque of 50 - 60 Nw x m.
- Tighten the fork leg closure screw to a
torque of 8 - 12 Nw x m.
- Locate the two brake caliper securing
screws (8 x 60) to a torque of 20 - 25
Nw x m. using Loctite. Finally turn the
wheel and operate the brake lever.