Checking The Front Fork Legs; Assembling The Front Fork Legs - Yamaha 2009 XP500Y TMAX Service Manual

Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4. Remove:
• Inner tube
M MMM M MMM M M MMM M M MMM M
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 careful-
ly.
ECA14190
NOTICE
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
• Avoid bottoming the inner tube into the out-
er tube during the above procedure, as the
oil flow stopper will be damaged.
L LLL L LLL L L LLL L L LLL L
EAS23010

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
M MMM M M MMM M MMM
L LLL L L LLL L LLL
4-53
• Outer tube
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Spring free length "a"
Out of specification → Replace.
Fork spring free length
303.9 mm (11.96 in)
Limit
297.8 mm (11.72 in)
3. Check:
• Damper rod "1"
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper "2"
Damage → Replace.
ECA4B51006
NOTICE
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
EAS23020

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
FRONT FORK