Yamaha YZF-R125 Service Manual: Assembling the front fork legs
The following procedure applies to both of the front fork legs.
WARNING
|
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 bottom of the inner tube. Be careful not to damage the inner tube. |
2. Lubricate:
- Inner tube's outer surface
3. Tighten:
- Damper rod bolt "1"
NOTE:
While holding the damper rod with the damper
rod holder "2" and T-handle "3", tighten the
damper rod bolt.
4. Install:
- Outer tube bushing "1"
- Washer "2"
(with the fork seal driver weight "3" and fork
seal driver attachment "4")
5. Install:
- Oil seal "1"
(with the fork seal driver weight "2" and fork seal driver attachment "3")
| CAUTION: Make sure the numbered side of the oil seal faces up. |
NOTE:
- Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
- Lubricate the outer surface of the inner tube with fork oil.
- Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
6. Install:
- Oil seal clip "1"
NOTE:
Adjust the oil seal clip so that it fits into the outer tube's groove.
7. Install:
- Dust seal "1"
(with the fork seal driver weight "2")
8. Fill:
- Front fork leg
(with the specified amount of the recommended
fork oil)
CAUTION:
|
9. After filling the front fork leg, slowly stroke the inner tube "1" up and down (at least ten times) to distribute the fork oil.
NOTE:
Be sure to stroke the inner tube slowly because the fork oil may spurt out.
10.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual air.
11.Measure:
Front fork leg oil level "a"
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
Out of specification 
Correct.
12.Install:
- Fork spring "1"
NOTE:
Install the spring with the smaller pitch "a" facing
up.
13.Install:
- O-ring
(to front fork cap) - Front fork cap
- Clip
NOTE:
- Before installing the front fork cap, lubricate its O-ring with grease.
- Insert the front fork cap into the inner tube, and then install the clip, making sure that the cap is securely held in place with the clip.
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.
WARNINGDo not attempt to straighten a bent inner ...
Installing the front fork legs
The following procedure applies to both of the
front fork legs.
1. Install:
Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure the inner tube end ...
Other materials:
Removing the starter clutch
1. Remove:
Starter clutch bolts "1"
NOTE:
While holding the generator rotor "2" with the
sheave holder "3", remove the starter clutch
bolts.
Do not allow the sheave holder to touch the
projection on the generator rotor.
...
Installing the rear brake caliper
1. Install:
Brake caliper "1"
Copper washers
Brake hose "2"
Union bolt "3"
WARNINGProper brake hose routing is essential to
insure
safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-33.
CAUTION:When installing the brake hose onto the
brake calip ...
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication
chart.
Place a stand under the engine to
raise the front wheel off the
ground. WARNING! To ...