Checking The Outer Tube; Checking The Front Fork Cap Bolt; Assembling The Front Fork - Yamaha WR450F(Y) 2009 Owner's Service Manual

The bending value is shown by one
half of the dial gauge reading.
Do not attempt to straighten a bent
inner tube as this may dangerous-
ly weaken the tube.

CHECKING THE OUTER TUBE

1. Inspect:
• Outer tube "1"
Score marks/wear/damage → Re-
place.
CHECKING THE FRONT FORK
CAP BOLT
1. Inspect:
• Front fork cap bolt "1"
• O-ring "2"
• Air bleed screw "3"
Wear/damage → Replace.

ASSEMBLING THE FRONT FORK

1. Wash the all parts in a clean sol-
vent.
2. Install:
• Damper rod "1"
To inner tube "2".
To install the damper rod into the
inner tube, hold the inner tube
aslant. If the inner tube is held ver-
tically, the damper rod may fall into
it, damaging the valve inside.
3. Install:
• Copper washer "1"
• O-ring "2"
• Base valve "3"
To inner tube "4".
4. Tighten:
• Base valve "1"
Base valve:
55 Nm (5.5 m•kg, 40
ft•lb)
• Use a damper rod holder "2" to lock
the damper rod "3".
®
• Apply the LOCTITE on the base
valve thread.
Damper rod holder:
YM-01494/90890-01494
5. Install:
• Spring guide "1"
• Locknut "2"
To damper rod "3".
• Install the spring guide with its
smaller dia.end "a" facing down-
ward.
• With its thread "b" facing upward,
fully finger tighten the locknut onto
the damper rod.
6-19
FRONT FORK
6. Install:
• Dust seal "1"
• Stopper ring "2"
• Oil seal "3"
• Oil seal washer "4"
• Slide metal "5"
To inner tube "6".
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vi-
nyl seat "a" with fork oil applied to
protect the oil seal lip.
• Install the oil seal with its manufac-
ture's marks or number facing the
axle holder side.
• Install the oil seal washer with its
projections "b" facing upward.
7. Install:
• Piston metal "1"
Install the piston metal onto the slot
on inner tube.