Warning!
- Make sure that the oil levels both front fork legs are equal.
- Uneven oil levels can result in poor handling and a loss of stability.
Note:
- When assembling the front fork leg, be sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
- Before assembling the front fork leg, make sure that all of the components are clean.
1. Install:
- damper rod (1)
- oil lock piece (2)
Warning! Always use new copper washers.
Caution! Allow the damper rod to slide slowly down the inner tube (3) until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube.
2. Lubricate: inner tube's outer surface
- Recommended lubricant: Yamaha fork and shock oil 10 W or equivalent
3. Tighten: damper rod bolt (1): 30 Nm (3.0 m·kg)
Note: While holding the damper rod with the T-handle (1) and damper rod holder (2), tighten the damper rod bolt (3).
- T-handle: 90890-01326
- Damper rod holder: 90890-01460
4. Install:
- outer tube bushing (1)
- seal spacer (with the fork seal driver weight (2) and adapter (3))
- Fork seal driver weight: 90890-01367
- Adapter: 90890-01381
5. Install: oil seal (1) (with the fork seal driver weight and adapter)
Caution! Make sure that the numbered side of the oil seal faces up.
Note: Before installing the oil seal, apply lithium soap base grease onto its lips.
6. Install: oil seal clip (1)
Note: Adjust the oil seal clip so that it fits into the outer tube groove.
7. Install: dust seal (1) (with the fork seal driver weight)
8. Fill: front fork leg (with the specified amount of the recommended fork oil)
- Quantity (each front fork leg): 0.464 L
- Recommended oil: Yamaha fork and shock oil 10W or equivalent
Caution!
- Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
- When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
Note: Be sure to stroke the inner tube slowly because the fork oil may spurt out.
10. Measure: front fork leg oil level (a)
Out of specification → Correct.
- Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring): 108 mm
Note: Hold the fork in an upright position.
11. Install:
- fork spring
- spring seat
- spacer
- O-ring
- cap bolt
Note:
- Install the fork spring with its smaller pitch up-word.
- Before installing the cap bolt, apply grease to the O-ring.
- Temporarily tighten the cap bolt.