Assembling The Front Fork Legs - Yamaha 2007 XP500 Service Manual

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
G
legs are equal.
Uneven oil levels can result in poor han-
G
dling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to
G
replace the following parts:
Inner tube bushing
G
Outer tube bushing
G
Oil seal
G
Dust seal
G
Before assembling the front fork leg, make
G
sure all of the components are clean.
1. Install:
Damper rod assembly "1"
G
Rebound spring "2"
G
ECA14210
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube "2" until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Install:
Oil flow stopper "1"
G
3. Lubricate:
Inner tube's outer surface "2"
G
Recommended oil
Fork oil 7.5W or equivalent
2
4. Install:
Outer tube (onto the inner tube)
G
Copper washer
G
Damper rod assembly bolt
G
5. Tighten:
Damper rod assembly bolt "1"
G
Damper rod assembly bolt
23 Nm (2.3 m•kg, 17 ft•lb)
LOCTITE®
NOTE:
Apply the locking agent (LOCTITE) to the
G
threads of the damper rod assembly bolt.
While holding the damper rod assembly with
G
the damper rod holder "2" and T-handle "3",
tighten the damper rod assembly bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
6. Install:
Outer tube bushing "1"
G
Washer "2"
G
(with the fork seal driver "3" and adapter "4")
4-61
FRONT FORK
1
New
New