Assembling The Front Fork Legs - Yamaha XT660Z 2008 Service Manual

EAS00659

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
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.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
– inner tube bushing
– outer tube bushing
– oil seal
– dust seal
– before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube busing
• Outer tube busing
• Oil flow stopper
• Damper rod "1"
• Rebound spring "2"
• Copper washer
New
WARNING
Always use new copper washer.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube "3" until it pro-
trudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
2. Lubricate:
• Inner tube's outer surface
Recommended lubricant
Fork oil 10W or equivalent
3. Tighten:
• Damper rod assembly bolt "1"
Damper rod assembly bolt
30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE
NOTE:
While holding the damper rod assembly with
the damper rod holder "2" and T-handle "3",
tighten the damper rod assembly bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
4. Install:
• Outer tube bushing "1"
(with the fork seal driver weight "3" and fork
seal driver attachment "4"
• Washer "2"
Fork seal driver weight
90890-01367
Fork seal driver attachment
90890-01374
4-53
FRONT FORK
®
New