Yamaha TDM850 User Manual page 132

7.20a Slide the damper into the tube..
19 Check the damper rod assembly
damage and wear, and renew it if necessary.
Holding the outside of the damper, pump the
rod in and out of the damper. If the rod does
not move smoothly in the damper it must be
renewed.
Reassembly
20 Insert the damper rod into the fork tube and
slide it into place so that it projects fully from the
bottom of the tube, then install the seat on the
bottom of the damper rod, making sure the
projection in the base of the seat locates with the
flat on the bottom of the damper
illustrations).
21 Oil the fork tube and bottom bush with the
specified fork oil and insert the assembly into the
slider. Fit a new copper sealing washer to the
damper rod bolt and apply a few drops of a
suitable non-permanent thread
compound, then install the bolt into the bottom of
the slider (see illustration). Tighten the bolt to
the specified torque setting. If the damper rod
rotates inside the tube, wait until the fork is fully
reassembled before tightening the bolt.
22 Push the fork tube fully into the slider, then
oil the top bush and slide it down over the tube
(see illustration). Press the bush squarely into
its recess in the slider as far as possible, then
install the oil seal washer with its flat side facing
up (see illustration). Either use the Yamaha
service tool or a
7.23 Make sure the oil seal is the correct
way up
7.20b . and fit the seat onto its bottom
for suitable piece of tubing to tap the bush fully into
place; the tubing must be slightly larger in
diameter than the fork tube and slightly smaller in
diameter than the bush recess in the slider. Take
care not to scratch the fork tube during this
operation; it is best to make sure that the fork
tube is pushed fully into the slider so that any
accidental scratching is confined to the area
above the oil seal.
23 When the bush is seated fully and squarely in
its recess in the slider, (remove the washer to
check, wipe the recess clean, then reinstall the
washer), install the new oil seal. Smear the seal's
(see
lips with fork oil and slide it over the tube so that
its markings face upwards and drive the seal into
place as
locking
7.22a Install the top bush ...
7.24 Install the retaining clip...
Frame, suspension and final drive 6»11
7.21 Apply a thread locking compound to
the damper rod bolt and use a new sealing
end
rcjflfllgjl Place the old oil seal on top llHillH^
HiNT
described above until the retaining clip groove is
visible above the seal (see illustration).
24 Once the seal is correctly seated, fit the
retaining clip, making sure it is correctly located
in its groove (see illustration).
25 Lubricate the lips of the new dust seal then
slide it down the fork tube and press it into
position (see illustration).
26 Slowly pour in the specified quantity of the
specified grade of fork oil and pump the fork and
damper rod at least ten times each to
7.22b ... followed by the washer
7.25 ... followed by the dust seal
washer
f f t protect It
0 ne new one 0
when driving the seal Into
place.
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