Inspection; Assembly - Yamaha YTZ250S 1986 Service Manual

NOTE: ______________________ _
For oil seal replacement alone, the following
steps can be left out.
10. Clamp the axle lug in a vise, and push the
inner tube all the way into the slider.
11. Use the damping-cylinder holding tool to
remove the holding bolt from the bottom
of the slider.
1. Cylinder holding tool
NOTE: ______________________ _
The holding bolt is locked with LOCTITE®
To remove it, tap it with a hammer several
times so that it can be loosened.
12. Slowly push the inner fork tube into the
outer fork tube, and then pull the fork
back quickly until it tops out. The slide
metal will be dislodged from the outer
fork tube after doing this several times.
Avoid bottoming the inner fork tube in the
outer fork tube. The taper spindle could be
damaged.
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Inspection
1. Examine fork inner tube for scratches
and straightness. If the tube is severely
scratched or bent, it should be replaced.
WARNING:
Do not attempt to straighten a fork tube,
since this may weaken the part
dangerously.
2. Inspect the slide metal. If damaged or ex-
cessively worn, replace it.
3. Check the seal outer seat. If leakage is
from this area, replace the seal. If this
does not care the leakage, replace the
outer tube.
4. Check the outer tube for dents. If any
dent causes the inner tube to "hang up"
during operation, the outer tube should
be replaced.
5. Check the free length of the springs.
Fork spring free length:
Short spring: 42.3 mm (1.67 in)
Long spring: 574.1 mm (22.6 in)
6. Check the O-ring on the cap bolt. If
damaged, replace it.
7. Inspect the damper rod seal and inner
tube slide bushing. If damaged or ex-
cessively worn, replace them.
Assembly
1. Make sure all components are clean
before assembly. Always install a new
fork seal. Do not re-use a seal.
2. Apply LOCTITE® to the threads of the
damper rod bolt, and reinstall the bolt.