4-44
4-45
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
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. Drain:
• Fork oil
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)
4. Remove:
• Damper rod bolt “1”
• Damper rod
NOTE:
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
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
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:
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
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:
– 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
CAUTION:
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
2. Lubricate:
• Inner tube’s outer surface
Fork spring free length
384.8mm
T-Handle
YSST-713
Summary of Contents for YZF-R15
Page 1: ...2008 SERVICE MANUAL YZF R15 20P F8197 E0 ...
Page 33: ...2 14 ELECTRICAL SPECIFICATIONS Coil resistance 54 0 66 0 Fuse 20 0A Ω Fuse ...
Page 46: ...2 27 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS A 1 2 3 4 5 6 7 ...
Page 48: ...2 29 LUBRICATION POINTS AND LUBRICANT TYPES 1 2 3 4 ...
Page 49: ...2 30 LUBRICATION POINTS AND LUBRICANT TYPES 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...
Page 50: ...2 31 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 2 3 4 1 5 7 6 4 ...
Page 52: ...2 33 CABLE ROUTING CABLE ROUTING 1 5 2 3 6 4 8 7 ...
Page 54: ...2 35 CABLE ROUTING A A B B C C A A C C B B A B C 1 2 3 4 5 4 5 6 6 7 8 9 10 11 10 11 12 12 ...
Page 56: ...2 37 CABLE ROUTING 1 2 5 4 3 ...
Page 60: ...2 41 CABLE ROUTING A A B C D E 1 2 3 4 5 6 7 8 9 10 A ...
Page 121: ...4 24 FRONT BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 ...
Page 249: ...7 8 THROTTLE BODY ...
Page 250: ...7 9 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 2 5 4 5 6 3 2 1 6 4 3 ...
Page 257: ......
Page 269: ...8 12 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Battery 42 Fuse ...
Page 271: ...8 14 CHARGING SYSTEM ...
Page 275: ...8 18 LIGHTING SYSTEM ...
Page 285: ...8 28 COOLING SYSTEM ...
Page 311: ...8 54 FUEL PUMP SYSTEM ...