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tony.mon wrote: ↑Mon Feb 05, 2024 11:41 am Today I ordered the tools, oil and seals I need for the Ohlins fork rebuild on my Aprilia. Although they're semi-automatic electronic forks the rebuild looks to be the same as normal mechanical ones apart from unplugging the loom connector at the fork cap. They're not nitrogen-filled, so at least that isn't needed.

It's now done 17k, so it's about time for a refresh, but it reminded me it was due by leaking oil at the recent MOT.

I already had a 43mm seal slider to fit the new seals, but needed to buy a fork leg compressor. I went for the full-length Sealey one rather than the little circular clamp with two handles. With the full length one you can do the job without a second pair of hands, plus it can be clamped in a vice to hold the leg at a convenient height.
(Thanks for the advice, Jonesy).

I also needed to order the (hopefully) correct pin socket to undo the fork caps. There's no nut, just eight holes, so you need a socket to fit with the pins of the correct diameter and pcd.
I'll know when it arrives whether I measured correctly!

I ordered Ohlins seals plus Ohlins dust seals and Ohlins 5w oil. I fully expect that an aftermarket set would be fine - and cheaper- but I prefer to spend a bit more first time round than have to do the job again in a few weeks, as I had to one time when I used pattern seals on a set of Blade forks I had on my Storm.

So far that lot has cost me £210, which is about what I would have spent taking the fork legs off and dropping them into a suspension specialist. But next time it will only cost me seals and oil.

I'll take some pics and post them afterwards. Ohlins forks are the same as fitted to a number of bikes, e.g. Yamaha, Ducati, etc, so this will be applicable to all Ohlins semi-auto forks. For instance Ducati call theirs Mechatronic, but they should be the same construction, just different dimensions, shimming, spring and oil weight and air gap, so are variations on a theme. But check!

It should be pretty similar to CyberCarl's old thread in the workshop knowledge base, (but without tipping the old oil down a drain)! We'll see, when the orders arrive.

Watty wrote:Organised delivery of the new toy

freeridenick wrote: ↑Thu Feb 08, 2024 7:13 pm

Watty wrote:Organised delivery of the new toy

Welcome back. You've been absent for a while I think?

Sent from my Pixel 5 using Tapatalk

tony.mon wrote: ↑Sat Feb 17, 2024 8:34 am Last few days in and off I've been refreshing the fork oil and seals on the Tuono, which is electronic so was new to me.
That's now done, but while I was there I wanted to check out a pulsing feeling I have been getting for a while when braking. It feels like a warped disc, so while I had the headstock stand in (after I finally found a way to lift it without the stand contacting the nose plastics) I checked it with a dti.

The lh side is a bit out, but not by much. The rh side is ok. The difficulty is that there isn't enough undrilled area on the disc for the dti to sit- normally there is a thin path on the outer edge, (but before you get to the rough outer edge of the rim where the pads don't contact) where you can measure accurately. On the Tuono's Brembo discs this is a very small track and the dti tip is slightly wider than the track, so I'm not getting a good reading.

So last year I tried cleaning and rotating the disc buttons. That hasn't fixed it, but I'll have one more try today in case I can get a result that way.

I've also tried removing the disc from the wheel and rotating it 180 degrees in case there is a cumulative machining tolerance error in both the wheel and disc carrier- if so, hopefully, rotating it will cancel them both out and it'll run true, or true enough, anyway.

Otherwise, it's new discs, and I don't have the money for a Brembo set...

I'll also bleed the brakes through with fresh fluid later. They've never been a problem, but the fluid is coming up to five years old now, and seeing as I pumped one piston out a bit far when doing the brake caliper spring clean and saw a little bit of brake fluid before I pushed it back, there's likely to be a bubble or two of air in that caliper anyway.

It would have cost me less in petrol going for a ride every day than it has playing with it in the garage...maybe I have too much time in my hands these days.

tony.mon wrote: ↑Sun Feb 18, 2024 7:30 pm I've taken the photos, Chris, I'm waiting until it's back on the road before I write up a "how-to" to make sure it all works as it should.