Checking The Front Fork Legs - Yamaha 2007 XP500 Service Manual

4. Remove:
Inner tube
G
MMMMMMMMMMMMMMMMMMMMMM
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but careful-
ly.
ECA14190
CAUTION:
Excessive force will damage the oil seal
G
and bushing. A damaged oil seal or bush-
ing must be replaced.
Avoid bottoming the inner tube into the
G
outer tube during the above procedure, as
the oil flow stopper will be damaged.
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EAS23010

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
Inner tube "1"
G
Outer tube "2"
G
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"
G
Out of specification → Replace.
Fork spring free length
405.0 mm (15.94 in)
Limit
400.0 mm (15.75 in)
3. Check:
Damper rod "1"
G
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
Oil flow stopper "2"
G
Damage → Replace.
4. Check:
Cap bolt
G
Damage/wear → Replace.
4-60
FRONT FORK