Removing The Front Fork Legs; Disassembling The Front Fork Legs - Yamaha 2009 XP500Y TMAX Service Manual

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EAS22960

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
• Lower bracket cover bolts
TIP
Before removing the lower bracket cover bolts,
support the front brake calipers so that there is
no strain placed on the brake pipe or speed sen-
sor lead.
3. Loosen:
• Upper bracket pinch bolt "1"
• Cap bolt "2"
• Lower bracket pinch bolts "3"
EWA13640
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
2
1
4. Remove:
• Front fork leg
EAS22980

DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Drain:
• Fork oil
TIP
Stroke the inner tube several times while drain-
ing the fork oil.
2. Remove:
• Dust seal "1"
• Oil seal clip "2"
(with a flat-head screwdriver)
ECA14180
NOTICE
Do not scratch the inner tube.
TIP
• Do not remove the fork leg protector from the
outer tube.
• If the front fork leg protector must be removed,
always install a new one.
3. Remove:
• Damper rod bolt "1"
3
• Copper washer
TIP
While holding the damper rod with the damper
rod holder "2" and T-handle "3", loosen the
damper rod bolt.
4-52
FRONT FORK
1
2

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