Inspection; Assembly - Yamaha YT175J 1982 Service Manual

S. Remove the retaining clip from the outer
fork tube, and pry out the fork seal. Be
careful not to damage the fork tube sur-
face.
Inspection
1. Examine the inner fork tube. If the tube
is severely scratched or bent, it should
be replaced.
WARNING:
Do not attempt to straighten a bent fork
tube; this may dangerously weaken the
tube.
2. Inspect the outer surface of the fork seal
seat in the outer fork tube. If this surface
is damaged, replace the outer fork tube.
If it is not damaged, replace the fork
seal.
3. Check the outer fork tubes for bents.
Replace the tube if it is ben ted .
4. Check the free length of the springs.
Fork spring free length:
341.1 mm (13.43 in)
5-11
5. Check the a-ring on the spring seat. If
it's damaged, replace it.
Assembly
1. Make sure all components are clean
before assembly. Always install a new
fork seal. Do not reuse a seal.
2. Apply oil to the fork seal, and install the
fork seal by pressing it in with a large
socket. Install the retaining clip.
3. Install the inner fork tube into the outer
fork tube.
4. Apply locktite® Stud N' Bearing Mount
(red) to the cylinder securing bolt, and
install the bolt and a copper washer into
the outer fork tube. Torque the bolt
specification.
Tightening torque:
23 Nm (2.3 m 'kg, 4.3 ft'lb)
5. Pour specified amount of oil into the in-
ner tube.
Fork oil:
Yamaha fork oil 10 Wt or equivalent
Oil capacity (Each fork):
116 cm
3
(4.0Slmp
OZ,
3.92 US oz)
Oil level: 245.5 mm (9.67 in)
(From top of inner tube fully
compressed without spring)
6. Reinstall the fork spring, spring seat and
stopper ring by depressing the spring
seat with a screwdriver.