Yamaha MBK X-MAX 300 2017, Service Manual

Page: 182 / 462

FRONT FORK
4-83
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
carefully.
NOTICE
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 out-
er tube during the above procedure, as the
oil flow stopper will be damaged.
EAS30208
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches
→
Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Fork spring free length “a”
Out of specification
→
Replace.
3. Check:
• Damper rod
Damage/wear
→
Replace.
Obstruction
→
Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage
→
Replace.
NOTICE
ECA14200
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
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.
WARNING
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.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Outer tube bushing
–Inner tube bushing
–Oil seal
–Oil seal clip
–Dust seal
–O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube bushing
2. Install:
• Oil flow stopper spring “1”
Fork spring free length
348.3 mm (13.71 in)
Limit
341.3 mm (13.44 in)
New