Checking The Front Fork Legs (For Yzf-R1); Assembling The Front Fork Legs (For Yzf-R1) - Yamaha YZF-R1 2020 Service Manual

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a
EAS30208
CHECKING THE FRONT FORK LEGS (for
YZF-R1)
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:
• Spring free length "a"
Out of specification → Replace.
Fork spring free length
219.5 mm (8.64 in)
Limit
215.1 mm (8.47 in)
G088921
3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
ECA19110
NOTICE
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material.
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a
4-94
FRONT FORK (for YZF-R1)
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
• Cap bolt "1"
• Cap bolt collar projection "2"
Cracks/damage → Replace.
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2
EAS30209
ASSEMBLING THE FRONT FORK LEGS (for
YZF-R1)
The following procedure applies to both of the
front fork legs.
EWA18360
WARNING
If both front fork legs are not filled with the
specified amount of the fork oil, it may cause
poor handling 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
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Base valve assembly
• Damper rod assembly
ECA22560
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube. Be careful not to
damage the inner tube.
2. Tighten:
• Damper rod assembly
Front fork damper rod assembly
40 N·m (4.0 kgf·m, 30 lb·ft)