Yamaha XMAX YP125R - Service manual > 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. Remove:

• Cap bolt "1"

NOTICE

When removing the cap bolt, take care not to damage the rectifier/regulator "2" with the tools.

TIP

If the cap bolt is difficult to loosen, slightly loosen the lower bracket pinch bolts "3".

3. Loosen:

• Lower bracket pinch bolts

WARNING

Before loosening the lower bracket pinch bolts, support the front fork leg.

Disassembling the front fork legs

The following procedure applies to both of the front fork legs.

1. Drain:

• Fork oil

TIP

Stroke the inner tube several times while draining the fork oil.

2. Remove:

• Dust seal "1"
• Oil seal clip "2" (with a flat-head screwdriver)

NOTICE

Do not scratch the inner tube.

3. Remove:

• Damper rod bolt "1"
• Copper washer
• Damper rod

TIP

While holding the damper rod with the damper rod holder "2" and T-handle "3", loosen the damper rod bolt.

Damper rod holder 90890-01294

Damping rod holder set YM-01300

T-handle 90890-01326

T-handle 3/8" drive 60 cm long YM-01326

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.

Fork spring free length 340.0 mm (13.39 in)

Limit 333.0 mm (13.11 in)

3. Check:

• Damper rod

Damage/wear → Replace.

Obstruction → Blow out all of the oil passages with compressed air.

• Oil flow stopper

Damage → Replace.

NOTICE

When disassembling and assembling the front fork leg, do not allow any foreign material 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 handling and a loss of stability.

TIP

When assembling the front fork leg, be sure to replace the following parts:

• Oil seal
• Dust seal
• Clip

Before assembling the front fork leg, make sure all of the components are clean.

1. Install:

• Damper rod "1"

NOTICE

Allow the damper rod to slide slowly down the inner tube "2" 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

Recommended oil Fork oil 10W or equivalent

3. Tighten:

• Damper rod bolt "1"

Damper rod bolt 30 Nm (3.0 m*kgf, 22 ft*lbf) LOCTITE

TIP

While holding the damper rod with the damper rod holder "2" and T-handle "3", tighten the damper rod bolt.

Damper rod holder 90890-01294

Damping rod holder set YM-01300

T-handle 90890-01326

T-handle 3/8" drive 60 cm long YM-01326

4. Install:

• Oil seal "1"(with the fork seal driver weight "2" and fork seal driver attachment "3")

Fork seal driver weight 90890-01367

Replacement hammer YM-A9409-7

Fork seal driver attachment (ø38) 90890-01372

Replacement 38 mm YM-A5142-1

NOTICE

Make sure the numbered side of the oil seal faces up.

TIP

• 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.

5. Install:

• Oil seal clip "1"

TIP

Adjust the oil seal clip so that it fits into the outer tube's groove.

6. Install:

• Dust seal "1"

(with the fork seal driver weight "2")

Fork seal driver weight 90890-01367

Replacement hammer YM-A9409-7

7. Fill:

• Front fork leg (with the specified amount of the recommended fork oil)

Recommended oil Fork oil 10W or equivalent

Quantity 128.0 cm³ (4.33 US oz, 4.51 Imp.oz)

NOTICE

• Be sure to use the recommended fork oil.

  Other oils may have an adverse effect on front fork performance.

• When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.

8. After filling the front fork leg, slowly stroke the inner tube "1" up and down (at least ten times) to distribute the fork oil.

TIP

Be sure to stroke the inner tube slowly because the fork oil may spurt out.

9. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.

TIP

Be sure to bleed the front fork leg of any residual air.

10.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.

Level 109.0 mm (4.29 in)

11.Install:

• Fork spring

Installing the front fork legs

The following procedure applies to both of the front fork legs.

1. Install:

• Front fork leg "1"

WARNING

Make sure the brake hose is routed properly.

TIP

Pull up the inner tube until it stops, and then tighten the lower bracket pinch bolts.

Lower bracket pinch bolt 23 Nm (2.3 m*kgf, 17 ft*lbf)

2. Lower bracket

2. Install:

• Cap bolt

(along with the O-ring )

Cap bolt 45 Nm (4.5 m*kgf, 32 ft*lbf)

NOTICE

When installing the cap bolt, take care not to damage the rectifier/regulator with the tools.

TIP

• Before installing the cap bolt, lubricate its Oring with grease.
• If the cap bolt is difficult to install, slightly loosen the lower bracket pinch bolts.

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