Assembling The Front Fork Legs - Yamaha FJR1300AS(X) Service Manual

Fork spring free length
262.0 mm (10.31 in)
Limit
257.0 mm (10.12 in)
3. Check:
• Damper rod assembly
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
ECA14200
CAUTION:
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
• Cap bolt O-ring
Damage/wear → Replace.
EAS23030

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
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
• 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
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube bushing "1"
• Oil flow stopper "2"
• Spring
• Damper rod assembly "3"
EC3P61028
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube "4" until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2
2. Lubricate:
• Inner tube's outer surface
Recommended oil
Suspension oil M1 or Ohlins R
& T43
3. Tighten:
• Damper rod assembly bolt
Damper rod assembly bolt
35 Nm (3.5 m·kg, 25 ft·lb)
LOCTITE
NOTE:
While holding the damper rod assembly with the
damper rod holder "1", tighten the damper rod
assembly bolt.
Damper rod holder
90890-01447
YM-01447
4-83
FRONT FORK
New
4
1
New
3
®