 |
Disassembling the front fork legs
|
|
|
|
The following procedure applies to both of the front fork legs.
Ч Remove:
dust seal 1
oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
4 - 77
FRONT FORK CHAS
Ш Drain:
fork oil
NOTE:
Stroke the outer tube several times while draining the fork oil.
Ъ Remove:
damper rod assembly bolt
NOTE:
While holding the cartridge cylinder with the damper rod holder 1 and T-handle 2, loosen the damper rod assembly bolt.
Damper rod holder 90890-01294, YM-01300
T-handle
YM-01326
Ы Remove:
inner tube
▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼
Ь Hold the front fork leg horizontally.
Ь Securely clamp the brake caliper bracket in a vise with soft jaws.
Ь Separate the inner tube from the outer tube by pulling the inner tube forcefully but care-fully.
CAUTION:
Э Excessive force will damage the oil seal and bushing. A damaged oil seal or bush-ing must be replaced.
Э Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.
▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲
4 - 78
FRONT FORK CHAS
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the front fork legs.
Ю Check:
inner tube 1
outer tube 2 Bends/damage/scratches → Replace.
WARNING
Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
А Measure:
spring free length a
Over the specified limit → Replace.
Spring free length limit 405.0 mm (15.94 in) <Limit>: 400.0 mm (15.75 in)
Б Check:
damper rod 1 Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-sages with compressed air.
oil flow stopper 2 Damage → Replace.
Б Check:
cap bolt
O-ring
Damage/wear → Replace.
4 - 79
FRONT FORK CHAS
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the front fork legs.
WARNING
Л Make sure that the oil levels in both front fork legs are equal.
Л Uneven oil levels can result in poor han-dling and a loss of stability.
|
|
|
NOTE:
М When assembling the front fork leg, be sure to replace the following parts:
inner tube bushing
outer tube bushing
oil seal
dust seal
М Before assembling the front fork leg, make sure that all of the components are clean.
Н Install:
damper rod 1
rebound spring 2
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.
О Install:
oil flow stopper 1
О Lubricate:
• inner tube’s outer surface 2
Recommended lubricant
Fork oil 7.5 W or equivalent
П Install:
outer tube (onto the inner tube)
• copper washer New
• damper rod assembly bolt
4 - 80
FRONT FORK CHAS
И Tighten:
damper rod assembly bolt 1
T.
R.
Damper rod assembly bolt 23 Nm (2.3 m · kg, 17 ft · lb)
LOCTITE®
NOTE:
Й Apply the locking agent (LOCTITE®) to the threads of the damper rod assembly bolt.
Й While holding the damper rod with the damper rod holder 2 and T-handle 3, tighten the damper rod assembly bolt.
Damper rod holder 90890-01294, YM-01300
T-handle
YM-01326
6. Install:
• outer tube bushing 1 New
Л washer 2
(with the fork seal driver weight 3 and fork seal driver attachment 4)
Fork seal driver weight 90890-01367, YM-A5142-4
Fork seal driver attachment (41 mm)
YM-A5142-2
М Install:
oil seal 1 New
(with the fork seal driver weight 2 and fork seal driver attachment 3)
CAUTION:
Make sure that the numbered side of the oil seal faces up.
4 - 81
FRONT FORK CHAS
NOTE:
Н Before installing the oil seal, apply lithium-soap-based grease onto its lips.
Н Apply fork oil onto the outer surface of the inner tube.
Н Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to pro-tect the oil seal during installation.
О Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer tube’s groove.
Р Install:
dust seal 1 New
(with the fork seal driver weight 2)
|
|
|
