Assembling The Front Fork Legs - Yamaha FJR1300A(D) Service Manual

Fork spring free length
345.0 mm (13.58 in)
Limit
340.0 mm (13.39 in)
3. Check:
• Damper rod assembly
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
ECA1MC1017
NOTICE
• 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.
4. Check:
• Cap bolt O-ring
Damage/wear → Replace.
EAS23030

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
EWA1MC1013
WARNING
• The specified oil levels are different for the
left and right front fork legs. Therefore, be
sure to fill each front fork leg with the
amount of fork oil specified for the fork leg.
• Incorrect oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Inner tube bushing
–Outer tube bushing 1
–Outer tube bushing 2
–Oil seal
–Dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube bushing
• Damper rod assembly
ECA1MC1018
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube until it protrudes
from the bottom of the inner tube. Be careful
not to damage the inner tube.
2. Lubricate:
• Inner tube's outer surface
Recommended oil
Suspension oil M1 or equivalent
3. Tighten:
• Damper rod assembly bolt
Damper rod assembly bolt
35 Nm (3.5 m·kg, 25 ft·lb)
LOCTITE®
TIP
While holding the damper rod assembly with the
damper rod holder "1", tighten the damper rod
assembly bolt.
Damper rod holder
90890-01447
YM-01447
4. Install:
• Outer tube bushing 2 (D = 51 mm (2.01 in), l
= 15 mm (0.59 in)) "1"
(with the slide metal installer "2" and fork seal
driver "3")
4-89
FRONT FORK
New
New