1996-On Tdm Models And Trx Models - Yamaha TDM850 User Manual

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maximum spring pressure is placed on the
damper rod head - tighten the damper Allen bolt
to the specified torque setting (see illustration
7.2).
30 Install the forks (see Section 6). Set the
spring pre-load adjuster
Section 12).
1996-on TDM models and TRX
models
Disassembly
31 Always dismantle the fork legs separately to
avoid interchanging parts and thus causing an
accelerated rate of wear. Store all components in
separate, clearly marked
illustration).
32 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 7.2).
33 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 (see illustration 7.4).
34 The fork top bolt comes as an assembly with
the pre-load adjuster and damping adjuster rod.
Unscrew the fork top bolt from the top of the fork
tube and lift it out until the damping adjuster rod
is clear.
35 Slide the fork tube down into the slider. On
TDM models withdraw the spring seat and spring
from the tube. On TRX models withdraw the
washer, spacer, spring seat and the spring from
the tube. Note which way up the spring is fitted.
36 Invert the fork leg over a suitable container
and pump the fork vigorously to expel as much
fork oil as possible.
37 Remove the previously slackened damper
rod bolt and its copper sealing washer from the
bottom of the slider. Discard the sealing washer
as a new one must be used on reassembly. If the
damper rod bolt was not slackened before
dismantling the fork, use the Yamaha service tool
(TDM models - pt. nos. 90890-01465 and 90890-
01326, TRX models - pt. nos. 90890-01388 and
90890-01326) to prevent the damper rod from
turning. This tool is passed down through the fork
tube and engages the damper rod head; a similar
tool can be easily made in the home workshop.
38 Invert the fork and withdraw the damper rod
from inside the fork tube (see illustration). If
required, slide the rebound spring off the damper
rod.
39 Carefully prise out the dust seal from the top
of the slider to gain access to the oil seal
retaining clip (see illustration 7.10). Discard the
dust seal as a new one must be used.
40 Carefully remove the retaining clip, taking
care not to scratch the surface of the tube (see
illustration 7.11).
41 To separate the tube from the slider it is
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1 Top bolt and preload
adjuster O-ring
Washer - TRX only
as required (see
Spacer - TRX only
Spring seat Spring
Damper rod and
rebound spring
8 Fork tube and
bottom bush
9 Damper rod seat
10 Dust seal
11 Retaining clip
12 Oil seal
containers (see
13 Washer
14 Top bush
15 Slider
16 Damper rod bolt and
sealing washer
7.31 Front fork components - 1996-on TDM models and TRX models
necessary to displace the top bush and oil seal. The
bottom bush should not pass through the top bush,
and this can be used to good effect. Push the tube
gently inwards until it stops against the damper rod
seat. Take care not to do this forcibly or the seat
may be damaged. Then pull the tube sharply
outwards until the bottom bush strikes the top bush.
Repeat this operation until the top bush and seal
are tapped out of the slider (see illustration 7.12).
42 With the tube removed, slide off the oil seal,
washer and top bush, noting which way up they fit
(see illustration 7.13). Discard the oil seal as a
new one must be used. Caution: Do not remove
the bottom bush from the tube unless it is to be
renewed.
43 Tip the damper rod seat out of the slider, noting
which way up it fits.
Inspection
44 Clean all parts in solvent and blow them
dry with compressed air, if available. Check
the fork
flaking of the chrome finish and excessive or
abnormal wear. Look for dents in the tube and
renew the tube in both forks if any are found.
tube for score marks, scratches,
Frame, suspension and final drive 6*13
Check the fork seal seat for nicks, gouges and
scratches. If damage is evident, leaks will occur.
Also check the oil seal washer for damage or
distortion and renew it if necessary.
45 Check the fork tube for runout (bending) using
V-blocks and a dial gauge, or have it done by a
dealer (see illustration 7.16). Yamaha do not
specify a runout limit, but if the tube is bent it
should be renewed.
7.38 Withdraw the damper rod and
rebound spring from the tube
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