Checking The Front Fork Legs; Assembling The Front Fork Legs - Yamaha XT250X Service Manual

4. Remove:
Inner tube
G
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
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
CAUTION:
Excessive force will damage the oil seal
G
and bushing. A damaged oil seal or bush-
ing must be replaced.
Avoid bottoming the inner tube into the
G
outer tube during the above procedure, as
the oil flow stopper will be damaged.
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EAS23010

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
Inner tube
G
Outer tube
G
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"
G
Out of specification → Replace.
Fork spring free length
482.0 mm (18.98 in)
Limit
472.3 mm (18.59 in)
3. Check:
Damper rod
G
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
Oil flow stopper
G
Damage → Replace.
ECA14200
CAUTION:
The front fork leg has a built-in damper ad-
G
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
G
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
Cap bolt
G
Damage/wear → Replace.
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.
4-43
FRONT FORK