Caution! Cover or mask off the instrument cluster and trim to prevent scratches.
Remove impact pad (2).
Remove clamp blocks (1).
Remove the handlebar and place it in front of the instrument cluster.
Unscrew hex nut (5).
Release clamping screws (3) at upper fork bridge.
Remove the upper fork bridge complete with the ignition lock.
Remove counter-tube (4).
Slacken round nut (1) with pin-wrench adapter, BMW # 31 6 521, then tighten to 25 Nm.
Turn forks back and forth twice from lock to lock, and leave the forks at the full left lock position.
Mark a 40 mm (1.58 in) arc with adhesive tape or similar (arrow) around the circumference of the locking plate at the steering head.
Align the mark on pin-wrench adapter, BMW # 31 6 521, with the right-hand end of the marked arc.
Note: 40 mm (1.58 in) around the circumference of the locking plate corresponds to an angle of rotation of 60°.
Turn the round nut clockwise until the pointer on pin-wrench adapter, BMW # 31 6 521, reaches the left-hand end of the marked arc.
Remove the mark/adhesive tape from the locking plate.
Caution! Check the mating faces of the fork bridge and knurled nut, rub down with an oilstone if necessary and clean.
Tighten the counter-tube.
Install fork bridge.
Firmly tighten locknut.
Tighten the clamping screws of the fork bridge.
Check play and freedom of movement.
Note: Use the punch marks (arrow) to align the handlebars as shown.
Warning! Begin by tightening the front securing screws (as viewed in the forward direction of travel) of the clamp blocks, then tighten the rear securing screws.
Install handlebars and impact pad.
Lift front wheel clear of the ground and perform final check.
With the front wheel off the ground, the weight of the forks must be enough to turn the steering all the way to the left and right full lock positions as soon as the handlebar is moved away from the straight-ahead position.
If local points of stiffness are detected when the handlebar is moved to and fro, renew the steering head bearings.
Tightening torques:
- Initial torque, round nut: 25 Nm
- Back off through angle of rotation: 60°
- Counter-tube to steering head bearing: 65 Nm
- Hexagon nut to counter-tube: 65 Nm
- Clamp screws at fork bridge: 21 Nm
- Handlebar to fork bridge: 21 Nm