Checking The Front Fork Legs - Yamaha 2012 TMAX XP500A Service Manual

TIP
While holding the damper rod with the damper
rod holder "2" and T-handle "3", loosen the
damper rod bolt.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
5. Remove:
• Inner tube
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a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
ECA14190
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
• Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.
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EAS23011

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube "1"
• Outer tube "2"
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Spring free length "a"
Out of specification → Replace.
Fork spring free length
303.9 mm (11.96 in)
Limit
297.8 mm (11.72 in)
3. Check:
• Damper rod "1"
Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
• Oil flow stopper "2"
Damage → Replace.
ECA14200
When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
4-84
FRONT FORK