Forks - Disassembly, Inspection And Reassembly; 1991 To 199S Tdm Models - Yamaha TDM850 User Manual

7 Top bolt
2 O-ring
3 Pre-load adjuster
4 Damping adjuster rod
5 Spring seat
6 Locknut
7 Spring
8 Damper
9 Fork tube
1 Bottom bush
0
1 Damper rod seat
1
1 Dust seal
2 1 Retaining clip
3
1 Oil seal
4 7 Washer
5
7 Top bush i
6
1 Fork slider 1
7 1 Sealing washer
8
1 Damper rod bolt J^_
9
7.1 Front fork components -1991 to 1995 TDM models
7.4a Unscrew the top bolt from the fork
tube...
7.4b ... and thread it off the adjuster if
required
Frame, suspension and final drive 6»9
7 Forks - disassembly,
inspection and reassembly

1991 to 199S TDM models

Disassembly
1 Always dismantle the fork legs separately to
avoid interchanging parts and thus causing an
accelerated rate of wear. Store
components in separate, clearly marked
containers (see illustration).
2 Before dismantling the fork, it is advised
that the damper rod bolt be slackened at this
stage. Compress the fork tube in the slider so
that the spring exerts maximum pressure on
the damper rod head, then have an assistant
slacken the damper rod bolt in the base of the
fork slider (see illustration).
3 If the fork top bolt was not slackened with
the fork in situ, carefully clamp the fork tube in
a vice equipped with soft jaws, taking care not
to overtighten or score its surface, and
slacken the top bolt.
4 Unscrew the fork top bolt from the top of
the fork tube (see illustration). The bolt can
remain threaded on the pre-load adjuster, but
remove it by holding the adjuster and
unscrewing it if required (see illustration).
5 Carefully clamp the fork slider in a vice and
slide the fork tube down into the slider a little
way (wrap a rag around the top of the tube to
minimise oil spillage) while, with the aid of an
assistant if necessary, keeping the damper
rod fully extended. Counter-hold the pre-load
adjuster and thread the locknut to the base of
its threads (see illustration). Now counter-
7.2 Slacken the damper rod Allen bolt
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7.5 Remove the pre-load adjuster as
described
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all
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