Yamaha YZF-R15, Service Manual

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FRONT FORK FRONT FORK
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Loosen:
• Handlebar pinch bolt “1”
• Handlebar bolt “2”
• Upper bracket pinch bolt “3”
• Lower bracket pinch bolt “4”
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
3. Remove:
• Front fork leg
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• Rubber cap
• Clip “1”
• Front fork cap “2”
(with O-ring)
• Fork spring
2
1
3
4
2. Drain:
• Fork oil
NOTE:
Stroke the inner tube several times while drain-
ing the fork oil.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
4. Remove:
• Damper rod bolt “1”
• Damper rod
2
1
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches → Replace.
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.
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
• When assembling the front fork leg, be sure to
replace the following parts:
– Outer tube bushing
– Oil seal
– Dust seal
– Clip
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Damper rod
2. Lubricate:
• Inner tube’s outer surface
Fork spring free length
T-Handle
YSST-713