Checking/Assembling The Front Fork Legs - Yamaha YZF-R25 Service Manual

4. Remove:
• Inner tube
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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.
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EAS30208
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• 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:
• Fork spring free length "a"
Out of specification → Replace.
Fork spring free length
297.8 mm (11.72 in)
Limit
**
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3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
ECA20550
NOTICE
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
EAS30209
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.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Inner tube bushing
–Outer tube bushing
–Oil seal
–Oil seal clip
–Dust seal
–O-ring
–Copper washer
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Oil flow stopper spring "1"
• Oil flow stopper "2"
• Damper rod ring "3"
• Rebound spring
• Damper rod "4"
• Inner tube bushing "5"
4-65
FRONT FORK
New