Assembling The Front Fork Legs - Yamaha TMAX XP500F 2015 Service Manual

2
2. Measure:
• Spring free length "a"
Out of specification → Replace.
Fork spring free length
295.1 mm (11.62 in)
Limit
289.2 mm (11.39 in)
3. Check:
• Damper rod assembly "1"
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.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1
EAS30209

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1
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
–Dust seal
–Oil seal clip
–O-ring
–Copper washer
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube outer surface
2. Install:
• Dust seal "1"
• Oil seal clip "2"
• Oil seal "3"
• Washer "4"
• Outer tube bushing "5"
• Inner tube bushing "6"
ECA14220
NOTICE
Make sure the numbered side of the oil seal
faces up.
TIP
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
4-84
FRONT FORK
Recommended oil
Suspension oil 01 or equivalent
New
New
New
New
New