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EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Fork spring free length "a"
Out of specification → Replace.
Fork spring free length
366 mm (14.41 in)
Limit
359 mm (14.13 in)
3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
• Oil flow stopper
Damage → Replace.
ECA14200
• The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
EAS23020
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
EWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• 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 all of the components are clean.
1. Install:
• Inner tube bushing "1"
• Damper rod "2"
• Spring "3"
• Oil flow stopper "4"
ECA3D81007
Allow the damper rod to slide slowly down
the inner tube "5" until it protrudes from
the bottom of the inner tube. Be careful not
to damage the inner tube.
3
4
2. Lubricate:
• Inner tube's outer surface
Recommended oil
Yamaha fork oil 10WT
4-50
FRONT FORK
New
5
New
1
2
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Troubleshooting
