Bitubo Service Manual
Contents
1. 5 DESCRIZIONE COMPLESSIVO CARTUCCIA ABB B CAR FMBLY DRAWING Via A Volta 24 35037 TEOLO PD Tel 049 9903475 Fax 049 9903447 AI SENSI ACCORDING TO T t OUE V AWING SHALL IETATA LA RI OT BE REPRODUCED PARZIAI E SENZA TTEN CONSENT FROM BITUBO NE SCRITTA DA PARTE ABB SPARE PARTS POSITION CODE DESCRIPTION OVERHAULING KIT 1 84500111 VOLANTINO REG COMPR COMP ADI KNB faf 2 904084 Oman e o 3 093203 RALLASTRISCIAMENTOTSHBERING _ ae rarpostreRioRe TUR o o Spe e OOOO O T S S E e 7 s4sso104 PERNO REGOLAZIONETADIOSTERPIN OO a o 8 84410104 MANICOTTO PRECARICO MOLLA HYDRAULIC PRELOAD SLEEVE 2 FERMO MOLLA SUPERIORE UPPER SPRING RETAINER xl O as LO E x 205 TFE S 13 O ring 3075 Di18 72x2 62 IF 8469060337 RANELLATWASHERDRSOITHRE 19 9936240037 ANECLOSEEGERRBSUNTTBS o sore a 90362400 ANELLOSEEGER in e o 22 445202 MOLLATNTERNATTOPOUTSPRING 33 GR50__ _ GRuPPOPISTONETPIsTONGROUP _ E _ st CI N o gt 835002 PISTONELIBEROTFLOATINGPISTON _________ E 26 jmo ome OOOO e S 3 raro eerioRe were a _ gt 9962927 GRANOMBASTGROBSCREW MBS 39 et DISTANZIALEINFERIORETLowERSPACER E 1 2 Sa subi su Il codice del componente va2. WARNING take note of the toward of insertion into the tube of the separator floating piston separator in this case shown in photo the plain surface of the piston is turned toward the outside of the pipe cartridge the concave toward the inside 4 Reverse the cartridge and to pour in the opposed extremity the hydraulic fluid Bitubo code 997631 up to the thread zone 5 Apply on the thread of the rod the teflon band 9 Now insert the rod with its hydraulic piston group into the cartridge tube WARNING Insert the rod very slowly for not move the position of the oil gas separator floating piston 6 Apply on the teflon band the Bitubo grease code 997615 10 Push the rod until the rebound spring arrives at the end of the threaded zone 7 Insert in the rod the washer of the rebound spring and then insert in the rod the new nut cap complete of new O ring and rod oil seals included in Kit Revision Ref GR0074 11 To position the washer on the rebound spring 8 Apply on the hydraulic piston the new sliding band 12 Slide down the cap nut along the rod then 16 Screw the lower cap until the distance of 1 2 screw it by hands mm from the O ring see photo to allow the insertion of gas with the Bitubo special tool 17 Apply on the cartridge tube as shown in hoto the Bitubo insertion gas tool cod 00231 13 Screw it using the Bitubo tool code 00214 o an g 14 verify that the floating
3. ABA 09 cod GR 0074 top cap of the fork legs Grease for seals code 997615 Suspension fluid code Bitubo cod 997631 Only for BW 037 ABBO9 cartridge washer code 84690603 RB8 seeger code 99362400 FUCHS Silkolene PRO RSF 5 WT eA ly v y i i is la i lt i Working tools BITUBO Tool for cap body 25mm code 00214 Cartridge lock tool 25mm code 00396 Pressure gauge for gas 25mm code 00231 Inserting tool for RB8 ring code 00405 Fork shaped tool code 00317 HHHO i GENERIC wrench 13 mm and 17mm socket wrench 32 mm Teflon tape 4 Remove the top cap Loctite n 243 DISMANTLY SEQUENCE 1 Remove the fork leg from the bike following the procedures described in the Workshop Manual Manufacturer s motorbike 2 Fasten the fork leg in the vice and with the socket wrench 32 mm to unscrew the top cap of the outer tube Lower by hand the spring and insert under the locking nut the fork shaped tool code 00317 i L L L L L 5 Remove the spring after remove the plastic 8 To hold in the vice the body cartridge insert it spacer if present in the Bitubo tool code 00396 as shown in photo i NAN v Mi nae gt le G le B Le IB MVP 9 Now lock the cartridge in vice and with the 17 mm wrench slowly unscrew the lower closing cap for depressurize the cartridge Only for BW037 ABBO9 Cartridge A remove the s
4. piston has not moved during the operations noticing an inferior measure of 1 2mm respect before these operations is to consider normal because due 18 Insert the Nitrogen gas at pressure of 8 0 bar to the tightening of the cap nut on the opposite side WARNING for the BW 037 ABBO9 cartridge the pressure recommend is 4 bar SAREL ai a 15 Replace the O ring of the lower cap and Screw it in the tube cartridge 19 Now tighten the cap using the 17mm wrench 20 Now lock in the wice the lower cap of the Only for BW 037 ABB09 Cartridge cartridge as shown in photo A apply to the threaded end of the rod the inserter tool code 00405 and insert the RB8 ring as t a 21 With the Bitubo tool code 00214 now tighten the cap nut so that also the lower tube cap jammed in vice will be tightened B Place the RB8 ring in its groove in the rod C Insert in the rod the washer original spring guide stopper with the working face down until the RB8 ring Verify that the ring is fully 22 insert the lower spring plate in the righ inserted in the hole of the washer position shape upward I I D Insert the spring guide tube original BMW 23 Screw the rod nut lock until the end of the 26 With the 13mm wrench on the rod nut and thread the 17mm wrench on the top cap tighten the nut to lock the top cap ry A 1 J gl J 24 Insert the spring and then the u
5. SERVICE MANUAL FORK CARTRIDGE ABB09 RACE SUSPENSION 50 100 9149 Ra o0 SERVICE MANUAL rm QUALITY SYSTEM CERTIFICATED FORK CARTRIDGE ABBO9 UNI EN ISO 9001 2008 Mod Service ABBO9 Pag 1 11 del 14 05 2010 OVERHAULING MANUAL SPARE PARTS LIST WARNING WARNING The fork cartridge is an important component of the motorbike and in this Service Manual is explained the correct method to revise it Please study and make certain that you fully understand all the instruction before handling this component if you have Remember that the cartridge is pressurized ant its may be very dangerous some component may be expulsed at very hight speed and cause serious damage to your healt and or other people nearby Read carefully this manual in order to follow the right s SIKOlene BITUBO USED AND RECOMMENDS LUBRICANTS orene All images data and or remarks in this booklet are given exlusively as an indication All data are modificable without advance notification WARNING All maintenance instruction in this manual must be i execute inside of an Autorized Service Repair Centre BITUBO can not be held responsible for any damage whatsoever to shock absorber or vehicle or injury to person if the intruction for fitting and maintenance of this manual are not followed exactly Necessary BITUBO spares 3 Holding the locking rod nut with the wrench 13 mm with the wrench 17 mm to unscrew the Overhauling kit
6. pper plastic spacer if present 25 Compress the spring and insert under the nut the Bitubo tool cod 00317 then screw the top fork cap 566556 Ny i S i bd N s i N O CO Solo per BW037ABB09 Only for BW037ABB09 Solo per BW037ABB09 Only for BW037ABB09 N N NOZ ent FASCIA PISTON SLI ISTONE RACE SUSPENSION
7. pring guide tube original BMW B remove the washer C remove the C ring from his housing 7 Remove the the lower spring holder plate 11 Measure and take note the distance of the WARNING remove the washer of the rebound oil gas separator floating piston from the edge spring under the cap nut of the cartridge 14 Extract the cartridge rod complete of its hydraulic piston and remove 12 Upset the cartridge place the locking bush cartridge at the opposite extremity fasten it in vice and with the Bitubo tool code 00214 loosen the cap nut 15 Remove from the hydraulic piston the sliding band 13 Unscrew completely the cap nut and pull it upward along rod pumping MOUNTING SEQUENCE 16 Drain in suitable container the cartidge oil 1 Apply Bitubo grease code 997615 in the thread of the cartridge tube Me 2 Replace the separator piston O ring seal Now insert the separator piston in the cartridge tube in the correct direction noticed when removed we p a x A H 17 To extract the separator floating piston insert the rod the thread side and to push it along the cartridge tube 3 Bring on the caliber the measure taken on at the time of removal therefore push the separator floating piston inside the cartridge up to the wanted distance from the tube edge 18 So this will make it possible to go out the floating piston to the opposite extremity of the tube cartridge
8. ria a seconda del modello tale codice pu essere richiesto facendo riferimento al modello specifico della cartuccia GR4641 d Li The code of the component change according to the model these codes can be asked according to the specific model of the cartridge 2 Specifico per BW037ABBO9 2 Specific for BW037ABB09 x3 Non presente in tutti 1 modelli x3 Not present in all model Attenzione l elenco e lo schema ricambi fanno riferimento alla maggior parte dei modelli di cartuccia ABB descritti in questo manuale Tuttavia esistono delle variazioni per applicazioni particolari 1 cui codici di ricambi devono essere richiesti di volta in volta Attention the spare parts list and scheme refer to most of the cartridge models included in this manual On the other hand there are some modifications therefore on placing your order please specify the exact code of your suspension NOTA NOTE Il Kit di revisione della cartuccia ABB cod GR0074 costituito dai codici delle posizioni indicate con X nella tabella e dalla fascia di tenuta del pistone cod 993824 presente all interno del gruppo pistone posizione 23 The cartridge ABA overhauling kit cod GR0074 includes the codes of the positions indicated X on the above spare parts list and the piston slide ring cod 993824 included inside the piston group position 23
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