Checking The Front Fork Legs; Assembling The Front Fork Legs - Yamaha FJR13AG Service Manual

Damper rod holder (ø32.5)
90890-01513
1
5. Remove:
• Inner tube
▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
ECA23490
NOTICE
• Excessive force will damage the bushings.
Damaged bushings must be replaced.
• Avoid bottoming the inner tube into the out-
er tube during the above procedure, as the
damper rod assembly will be damaged.
▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲
EAS31650

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.
▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼
▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲
4-99
FRONT FORK (FJR13AG)
2. Measure:
• Spring free length "a"
Out of specification → Replace.
Fork spring free length
314.0 mm (12.36 in)
Limit
307.7 mm (12.11 in)
3. Check:
• Damper rod assembly
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
ECA20300
NOTICE
• The front fork leg has a built-in damper rod
assembly and a very sophisticated internal
construction, which are particularly sensi-
tive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
EAS31651

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
EWA18480
WARNING
• The specified oil levels are different for the
left and right front fork legs. Therefore, be
sure to fill each front fork leg with the
amount of fork oil specified for the fork leg.
• Incorrect 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 1
–Outer tube bushing 2
–Oil seal
–Dust seal