User Guide

Chapter 5 Part A Steering, suspension and final drive (XV535 models)
5A-5
5.6a This special Yamaha tool is used to keep the damper rod
from turning when its bolt is loosened or tightened
1 Handle 2 Adapter
5.6b Loosen the damper rod bolt with an Allen wrench .
5.6c ... and remove the bolt and its
copper washer - use a new copper
washer during reassembly
5.7 Remove the damper rod and the
rebound spring - don't separate the
Teflon ring from the damper rod
unless you plan to replace it
5.8 To separate the inner and outer fork
tubes, pull them apart firmly several
times - the slide hammer effect
will pull the tubes apart
6 Prevent the damper rod from turning using a holding handle
(Yamaha tool no. YM-01326, part no. 90890-01326) and adapter
(Yamaha tool no. YM-01300-01, part no. 90890-01294) (see illustration)
passed down through the fork inner tube to engage the damper rod
head. Unscrew the Allen bolt at the bottom of the outer tube and remove
the copper washer (see illustrations). Note: If you don't have access to
these tools, a piece of hardwood dowel can be used instead. Cut a taper
on the end of the dowel to fit into the damper rod head. Another
alternative is to loosen the damper rod bolt before removing the fork cap;
the pressure of the fork spring will keep the damper rod from turning.
7 Pull out the damper rod and the rebound spring (see illustration).
Don't remove the Teflon ring from the damper rod unless a new one
will be installed.
8 Hold the outer tube and yank the inner tube away from it,
5.14 Fit the oil lock piece onto the exposed end of
the damper rod
repeatedly (like a slide hammer), until the seal and outer tube guide
bushing pop loose (see illustration).
9 Remove the oil seal and slide bushing from the inner tube, and
the oil lock piece from the outer tube.
Inspection
10 Clean all parts in solvent and blow them dry with compressed air,
if available. Check the inner and outer fork tubes, the guide bushing and
the damper rod for score marks, scratches, flaking of the chrome and
excessive or abnormal wear. Look for dents in the tubes and replace
them if any are found. Check the fork seal seat for nicks, gouges and
scratches. If damage is evident, leaks will occur around the seal-to-
outer tube junction. Replace worn or defective parts with new ones.
11 Have the inner fork tube checked for runout at a dealer service
department or other repair shop. Warning: If it is bent, it should not be
straightened; replace it with a new one.
12 Measure the overall length of the long (fork) spring and check it
for cracks and other damage. Compare the length to the minimum
length listed in this Chapter's Specifications. If it's defective or sagged,
replace both fork springs with new ones. Never replace only one
spring.
Reassembly
Refer to illustrations 5.14, 5.17, 5.18, 5.19 and 5.20
13 Install the rebound spring on the damper rod. Install the damper
rod in the inner fork tube, then let it slide slowly down until it protrudes
from the bottom of the inner fork tube.
14 Install the oil lock piece over the end of the damper rod that
protrudes from the fork tube (see illustration).