EAS00646

FRONT FORK

FRONT FORK

CHAS (3^3^)

S& 45Nm(4.5m • kg, 32.5 ft • lb)

gR 30Nm(3.0m • kg, 21.7 ft • lb)

Order

1

2

3

4

5

Job/Part

Removing the front fork legs

Front fork upper cover

Reflector

Front fork cover(left and right)

Front wheel

Cable guide

Cap bolt

O-ring

Lower bracket pinch bolt

Front fork leg

Q’ty

Remarks

Remove the parts in the order listed.

Refer to”LEG SHIELD1,2 “ in chapter 3.

Refer to”FRONT WHEEL AND BRAKE”.

1

1

1

1

1

Refer to”REMOVING THE FRONT

FORK LEGS” and “INSTALLING THE

FRONT FORK LEGS”

For installation, reverse the removal procedure.

4-19

EAS00648

FRONT FORK C H A S (3^3^)

(D

3R 23Nm(2.3m • kg, 16.6 ft < lb)

Order Job/Part

Disassembling the front fork legs

Fork oil

1 Fork spring

2 Damper rod bolt/Copper washer

3 Damper rod

4 Rebound spring

5 Inner tube

6 Dust seal

7 Oil seal clip

8 Oil seal

9 Outer tube

Remarks

Q’ty

Remove the parts in the order listed.

Drain.

1

1/1

1

1

1 Refer to”DISASSEMBLING THE

1 FRONT FORK LEGS” and “ASSEM-

1 BLING THE FRONT FORK LEGS”

1

1

For assembly, reverse the disassembly procedure.

4-20

FRONT FORK

CHAS (3^3^)

EAS00651

REMOVING THE FRONT FORK LEGS

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

1. Stand the scooter on a level surface. w

Securely support the scooter so that there is no danger of it falling over.

NOTE:

Place the scooter on a suitable stand so that the front wheel is elevated.

2. Remove:

8front fork upper cover

8front fork cover (left and right)

Refer to “LEG SHIELD1,2”in chapter 3.

8front wheel

Refer to “FRONT WHEEL AND BRAKE”.

3. Loosen:

8lower bracket pinch bolt 1

4. Remove:

8cap bolt 2

(with a 10 -mm hexagonal wrench3) w

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

5. Remove:

8front fork leg

4-21

EAS00653

DISASSEMBLING THE FRONT FORK LEGS

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

1. Remove:

8fork spring 1

FRONT FORK

2. Drain:

8fork oil

3. Remove:

8damper rod assembly b o l t 1

NOTE:

While holding the damper rod with the damper rod holder 2 and T-handle3, loosen the damper rod assembly bolt.

/ •

Damper rod holder

90890-01294(YM-01300-1)

T-handle

90890-01326(YM-01326)

4. Remove:

8damper r o d 1

8spring

8inner t u b e 2

4-22

5. Remove:

8dust seal

8oil seal clip 1

(with a flat-head screwdriver) c C

Do not scratch the inner tube.

FRONT FORK

CHAS (3^%

6. Remove:

8oil s e a l 1 c C

Never reuse the oil seal.

8 R a g 2

EAS00656

CHECKING THE FRONT FORK LEGS

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

1. Check:

8 inner t u b e ®

8 outer tube (2)

Bends/damage/scratches -* Replace. w

Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

4-23

2. Measure:

8 spring free length a

Out of specification -* Replace.

Spring free length

202.2mm(7.96in)

<Limit> :198.2mm(7.80in)

3. Check:

8 damper r o d ®

Damage/wear -* Replace.

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

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FRONT FORK

EAS00658

ASSEMBLING THE FRONT FORK LEGS

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

NOTE:

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

- oil seal

- dust seal

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

1. Install:

8damper rod assembly 1

8rebound spring 2 c C

Allow the damper rod assembly to slide slowly down the inner t u b e 3 until it protrudes from the bottom of the inner tube.

Be careful not to damage the inner tube.

2. Lubricate:

8inner tube’s outer surface

Recommended lubricant

Fork oil 10W or equivalent

3. Tighten:

8 Copper washer New

8 damper rod assembly bolt (T)

X I 23 Nm (2.3 m * kg, 16.6 ft * lb)

NOTE:

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

Damper rod holder

90890-01294(YM-01300-1)

T-handle

90890-01326(YM-01326)

4-24

V •

FRONT FORK

CHAS (3^3^)

4. Install:

8oil seal 1 New

(with the fork seal driver weight 2 and adapter 3 )

^

Fork seal driver weight

90890-01367(YM-A9409-7)

Adapter

90890-01400(YM-A9409-3 ) c C

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

NOTE:

8 Before installing the oil seal, lubricate its lips with lithium soap base grease.

8 Lubricate the outer surface of the inner tube with fork oil.

8 Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation.

5. Install:

8oil seal c l i p 1

NOTE:

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

4-25

6. Fill:

8front fork leg

(with the specified amount of the recommended fork oil)

*® Quantity (each front fork leg)

0.042 L (0.038 Imp qt, 0.046 US qt)

Recommended oil

Fork oil 10W or equivalent

4-26

FRONT FORK

CHAS (3^3^)

NOTE:

8 While filling the front fork leg, keep it upright.

8 After filling, slowly pump the front fork leg up and down to distribute the fork oil.

7. Install:

8fork spring 1

NOTE:

8 Install the spring with the smaller pitch facing down .

EAS00663

INSTALLING THE FRONT FORK LEGS

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

1. Install:

• front fork leg

• o-ring New

• cap bolt

NOTE:

Pull up the inner tube until it stops, then install the cap bolt .

2. Tighten:

• cap bolt (T)

X | 45 Nm (4.5 m * kg, 32.5 ft * lb)

• lower bracket pinch bolt (2)

X | 30Nm(3.0m

* kg, 21.7ft

* lb)