Assembling The Front Fork Legs - Yamaha 2009 Diversion XJ6S Service Manual

EAS23020

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
EWA13660
WARNING
Make sure the oil levels in both front fork
G
legs are equal.
Uneven oil levels can result in poor han-
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dling and a loss of stability.
TIP
When assembling the front fork leg, be sure to
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replace the following parts:
–Inner tube bushing
–Oil seal
–Dust seal
Before assembling the front fork leg, make
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sure all of the components are clean.
1. Install:
Inner tube bushing
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Oil flow stopper
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Damper rod assembly "1"
G
Copper washer
New
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ECA14210
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.
1
2. Lubricate:
Inner tube's outer surface
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Recommended lubricant
Suspension oil 01 or equivalent
3. Tighten:
Damper rod assembly bolt "1"
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Damper rod assembly bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
LOCTITE®
New
TIP
While holding the damper rod assembly with the
damper rod holder "2" and T-handle "3", tighten
the damper rod assembly bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4. Install:
Outer tube bushing "1"
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(with the fork seal driver "2" and fork seal at-
tachment "3")
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø41)
90890-01381
Replacement 41 mm
YM-A5142-2
5. Install:
Washer
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Oil seal "1"
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(with the fork seal driver and fork seal attach-
ment)
ECA14220
NOTICE
Make sure the numbered side of the oil seal
faces up.
4-65
FRONT FORK
New