Checking The Front Fork Legs; Assembling The Front Fork Legs - Yamaha XG250 Service Manual

vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
ECA14190
CAUTION:
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
●
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 "1"
●
Outer tube "2"
●
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2
2. Measure:
Spring free length "a"
●
Out of specification → Replace.
3. Check:
1
ECA14200
CAUTION:
●
●
4. Check:
1
EAS23020

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
EWA13660
●
4-44
Fork spring free length
478.0 mm (18.82 in)
Limit
468.4 mm (18.44 in)
Damper rod
●
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
Oil lock piece
●
Damage → Replace.
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.
Cap bolt "1"
●
Damage/wear → Replace.
WARNING
Make sure the oil levels in both front fork
FRONT FORK
1