Assembling The Front Fork Legs - Yamaha XT1200Z(Z) 2010 Service Manual

ECA14200
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
• Cap bolt O-ring
Damage/wear → Replace.
EAS23041

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
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
–O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube's outer surface
Recommended oil
Suspension oil 01 or equivalent
2. Install:
New
• Dust seal "1"
New
• Oil seal clip "2"
• Oil seal "3" New
• Washer "4"
• Outer tube bushing "5"
• Inner tube bushing "6"
ECA23P1034
NOTICE
Make sure to face the numbered side of the
oil seal toward the bottom end of the inner
tube.
New
New
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.
5 New
4
6 New
3. Install:
• Outer tube
(to the inner tube)
4. Install:
• Outer tube bushing "1"
• Washer "2"
(with the fork seal driver "3")
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46
mm)
YM-01442
3
2
1
4-87
FRONT FORK
3 New
2 New
1 New