Yamaha SR400 2014, Service Manual

Page: 156 / 342

FRONT FORK
4-40
4. 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 careful-
ly.
NOTICE
ECA2RD1019
• 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 lock piece 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.
WARNING
EWA13650
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.
3. Check:
• Damper rod
Damage/wear

Replace.
Obstruction

Blow out all of the oil passag-
es with compressed air.
• Oil lock piece
Damage

Replace.
4. Check:
•
Cap bolt
Damage/wear

Replace.
EAS23021
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:
–Slide metal
1
2
3
Fork spring free length
492.9 mm (19.41 in)
Limit
483.0 mm (19.02 in)
1
2