Yamaha XV19SX(C), Service Manual

Page: 225 / 494

FRONT FORK
4-72
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EAS23010
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:
• 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.
CAUTION:
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.
4. Check:
• Cap bolt O-ring
Damage/wear
→
Replace.
EAS23020
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.
NOTE:
• When assembling the front fork leg, be sure to
replace the following parts:
–Inner tube bushing
–Outer tube bushing
–Oil seal
–Dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube bushing “1”
• Damper rod “2”
• Rebound spring
• Spring “3”
• Oil flow stopper “4”
CAUTION:
EC1D71012
Allow the damper rod to slide slowly down
the inner tube “5” until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
Fork spring free length
XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C):
273.9 mm (10.78 in)
XV19CS(C)/ XV19C(C):
407.0 mm (16.02 in)
Limit
XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C):
268.4 mm (10.57 in)
XV19CS(C)/ XV19C(C):
398.9 mm (15.70 in)