Removal And Disassembly - Yamaha YTZ250S 1986 Service Manual

Removal and Disassembly
To prevent an accidental explosion of air,
the following instructions should be
observed:
1. Use only air or nitrogen for filling.
Never use any other gas. An explo-
sion may result.
2. Never throw the front fork into fire.
3. Before removing the cap bolts or
front forks, be sure to extract the air
from the air chamber completely.
1. Place the machine on a suitable stand to
keep it stable while the front wheel and
forks are removed.
2. Let the air out of the forks, and remove
the cap bolts.
3. Remove the front wheel and front brake
caliper. Loosen the fork tube pinch bolts,
and remove the forks.
4. Remove the rubber boot, short spring,
washer, and long spring.
5. Remove the dust seal and snap ring from
the top of the outer tube.
4-13
1. Dust seal 2. Snap ring
6. Fill the fork completely with fork oil and
reinstall the cap bolt. Depress the air
valve until oil flows out.
7. Place a spacer on top of the cap bolt, and
place the fork leg in a hand press as il-
lustrated. The spacer will keep the press
from contacting the air valve.
If the inner tube is abruptly contracted or
air enters the inner tube, the oil may spurt
out or the oil seal may spring out. Never
touch the inner tube during disassembling
operation. Also wrap the oil seal with a
rag for safety.
1. Turn slowly
2. Spacer
3. Wrap with rag
8. Wrap a rag around the top of the slider,
and slowly turn the handle of the press
until the oil seal is pushed out of the
slider.
9. Remove the oil seal. Discard the oil seal,
as the seal must always be replaced
whenever the fork is disassembled.