Front shock removal

[ErikM]

Hey fellers I need to remove my front shock (ohlins) to put the stock back in. I had the dealer do it before but it really looks easy. Couple of question I hope one of you pro's can answer.

To get the gas tank moved ,I don't need to completly remove it just slide it back a couple of inches do I just remove the trim from the front of the tank and and all will be clear?

As far as the shock removal goes I was going to hold up the front with tie downs to the ceiling rather than a jack under the motor. It doesn't look as if I need to really drop down the front wheel seems to be enough room to get the shock out, any things I should know about there??

Any and all input is much appreciated, wish I had a factory work manaul but getting the rear out was a snap looks like the front should'nt be to bad.

[deilenberger]

You also have to unfasten all the screws at the rear of the tank that go to the sidepanels on the bike, and remove the throttle body covers. Lots of T15 screws.. Then you have to remove the bolt holding the tank down (left side, under side panel.) With the front panel loosened (you can leave it in place) you can then slide the tank back a few inches.

I prefer the jack under the engine since it is helpful to get the wheel down further in getting the shock out.

I've done this about 4-5 times now - and it takes about 1/2 hour or so to do. You may want to use a heat-gun on the wishbone bolt (bottom shock mount) - if the dealer did it correctly, there is some loctite on the bottom bolt. Heating it makes it easier to remove (T45 from memory..)

[Matt]

I have cut and past this from a R12R manual if it helps, you really need the asociated picture but I can not see how to attach it to this post

Removing front spring strut

Affix masking tape arrow to the leading link and to both cylinders to prevent damage
Remove nut (1), while counter-holding at the spring-strut stud.
Remove washer (2) and rubber buffer (3)
Heat screw (6) and remove.
Raise the motorcycle on the engine lifter.
The leading link is lowered.
Pull the spring strut forward and remove.
Remove spacing sleeve (4) and rubber buffer (5).

Installing spring strut

Clean the threads of the spring strut.
Install rubber buffer (5) with the collar up.
Install spacing sleeve (4).
Install spring strut.
Install rubber buffer (3) with the collar down and install washer (2).
Apply thread-locking compound to nut (1) and tighten until hand-tight.
Install screw (6).
Tighten nut (1), while counter-holding at the spring-strut stud.

Tightening torques
Spring strut, front, at bottom to leading link
Replace screw, grease head, M10 x 50 34 Nm

Spring strut to front frame
Hex nut M10 34 Nm

[ErikM]

Thanks guys, all done, went smooth as silk until a friend that was helping me dropped the nut for the top of the shock into the bowels of the bike necessitating the removal of the gas tank, even that wasn't a big deal except that I'd just filled the tank, but it all got put together fine no scratches or left over parts.

[NeilS]

Erik,

Since you've just done it, can you say anything about how the fuel lines are supposed to be routed in the plastic clips at the left rear of the tank? My dealer's slob/mechanic screwed this up while doing the recalls, and I can't figure out how it was originally.

TIA,

[ErikM]

Neil I'm sorry but I was the one holding the tank not connecting the fuel fittings.

[BigEasy]

Thanks guys, all done, went smooth as silk until a friend that was helping me dropped the nut for the top of the shock into the bowels of the bike necessitating the removal of the gas tank, even that wasn't a big deal except that I'd just filled the tank, but it all got put together fine no scratches or left over parts.

That's fun, I know because I changed mine myself and dropped the nut, I too had a full tank of gas