Assembling The Front Fork Legs - Yamaha 2012 TMAX XP500A Service Manual

EAS23031

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
- Oil seal clip
- O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Damper rod "1"
• Rebound spring "2"
ECA14210
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. Install:
• Oil flow stopper "1"
3. Lubricate:
• Inner tube's outer surface "2"
Recommended oil
Fork oil 10W or equivalent
4. Install:
• Inner tube
(into the outer tube)
• Copper washer
• Damper rod bolt
5. Tighten:
• Damper rod bolt "1"
Damper rod bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
LOCTITE®
TIP
While holding the damper rod with the damper
rod holder "2" and T-handle "3" tighten the
damper rod bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-85
FRONT FORK
New