4-85
FRONT FORK
3. Check:
• Damper rod assembly
Damage/wear Replace.
Obstruction Blow out all of the oil passag-
es with compressed air.
ECA19110
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
EAS30209
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
EWA13660
• 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.
• 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
– Copper washer
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube outer surface
2. Install:
• Dust seal “1”
• Oil seal clip “2”
• Oil seal “3”
• Washer “4”
• Outer tube bushing “5”
• Inner tube bushing “6”
NOTICE
ECA14220
Make sure the numbered side of the oil seal
faces up.
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
3. Install:
• Outer tube
(to the inner tube)
4. Install:
• Outer tube bushing “1”
• Washer “2”
(with the fork seal driver “3”)
Recommended oil
Yamaha Suspension Oil 01
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