Assembly - Yamaha XZ550RJ 1982 Service Manual

2. Inspect the outer surface of the fork seal
seat in the outer fork tube. If this surface is
damaged, replace the outer fork tube. If it is
not damaged, replace the fork seal.
3. Check the outer fork tubes for dents. Re-
place the tube if it is dented.
4. Check the free length of the springs.
Fork spring free length:
461 mm (22.1 in)
5. Check the 0-ring on the cap bolt. If it's dam-
aged, replace it.
1. O-ring

Assembly

1. Make sure all components are clean before
assembly. Always install a new fork seal. Do
not reuse a seal.
2. Apply oil to the fork seal, and install the fork
seal by pressing it in with a large socket. In-
stall the retaining clip.
3. Install the dust seal into the outer fork tube.
4. Install the damper rod assembly into the in-
ner fork tube. Hold the damper rod with the
front fork cylinder holder.
5. Put the taper spindle on the damper rod.
6. Hold the inner fork tube, and carefully install
the outer fork tube over the taper spindle.
7. Apply Loctite®
curing bolt, and install the bolt and a copper
washer into the outer fork tube. Torque the
bolt to specification.
Tightening torque:
26 Nm (2.6m-kg, 19fflb)
(red) to the cylinder se-
8. Pour the specified amount of fork oil into the
inner fork tube.
Fork oil capacity:
3
257cm (9.0 Imp oz, 8.7 US oz)
Fork oil level:
152mm (6.0 in)
(From top of inner tube fully compressed with-
out spring.)
Recommended oil:
Yamaha fork oil 15 wt or equivalent
9. Install the fork spring and cap bolt with a
new 0-ring into the inner fork tube. Finger
tighten the cap bolt.
NOTE:
The fork spring must be installed with the smaller
pitch side facing upward as shown.
10. Install the fork into the brackets. Make the
top of the inner fork tube level with the top of
the handle crown.
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