2000 YAMAHA YZ426F Front fork

5 - 33
CHASFRONT FORK
5. Install:
lSpring guide 1
lLocknut 2
To damper rod 3.
NOTE:
lInstall the spring guide with its cut a facing
upward.
lWith its thread b facing upward, fully finger
tighten the locknut onto the damper rod.
6. Install:
lDust seal 1
lStopper ring 2
lOil seal 3
lPlain washer 4
lSlide metal 5
To inner tube 6.
NOTE:
lApply the fork oil on the inner tube.
lWhen installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
lInstall the oil seal with its manufacture’s
marks or number facing the axle holder side.
New
New
7. Install:
lPiston metal 1
NOTE:
Install the piston metal onto the slot on inner
tube.
New
8. Install:
lOuter tube 1
To inner tube 2.

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CHASFRONT FORK
9. Install:
lSlide metal 1
lPlain washer 2
To outer tube slot.
NOTE:
Press the slide metal into the outer tube with
fork seal driver 3.
Fork seal driver:
YM-01442/90890-01442
10. Install:
lOil seal 1
NOTE:
Press the oil seal into the outer tube with fork
seal driver 2.
Fork seal driver:
YM-01442/90890-01442
11. Install:
lStopper ring 1
NOTE:
Fit the stopper ring correctly in the groove in
the outer tube.
12. Install:
lDust seal 1
NOTE:
Apply the lithium soap base grease on the
inner tube.

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CHASFRONT FORK
13. Check:
lInner tube smooth movement
Tightness/binding/rough spots ®
Repeat the steps 2 to 12.
14. Compress the front fork fully.
15. Fill:
lFront fork oil
Until outer tube top surface with recom-
mended fork oil 1.
ACHTUNG:CAUTION:
lBe sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
lNever allow foreign materials to enter the
front fork.
Recommended oil:
Suspension oil “01”
16. After filling, pump the damper rod 1
slowly up and down more than 10 times
to distribute the fork oil.
17. Fill:
lFront fork oil
Until outer tube top surface with recom-
mended fork oil once more.
18. After filling, pump the outer tube 1 slowly
up and down (about 200 mm (7.9 in)
stroke) to distribute the fork oil once
more.
NOTE:
Be careful not to excessive full stroke. A stroke
of 200 mm (7.9 in) or more will cause air to
enter. In this case, repeat the steps 15 to 18.

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CHASFRONT FORK
19. Wait ten minutes until the air bubbles
have been removed from the front fork,
and the oil has dispense evenly in system
before setting recommended oil level.
NOTE:
Fill with the fork oil up to the top end of the
outer tube, or the fork oil will not spread over to
every part of the front forks, thus making it
impossible to obtain the correct level.
Be sure to fill with the fork oil up to the top of
the outer tube and bleed the front forks.
20. Measure:
lOil level (left and right) a
Out of specification ® Adjust.
NOTE:
Be sure to install the spring guide 2 when
checking the oil level.
WARNING
Never fail to make the oil level adjustment
between the maximum and minimum level
and always adjust each front fork to the
same setting. Uneven adjustment can
cause poor handling and loss of stability.
Standard oil level:
130 mm (5.12 in)
Extent of adjustment:
80 ~ 150 mm (3.15 ~ 5.91 in)
From top of outer tube with
inner tube and damper rod 1
fully compressed without
spring.

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CHASFRONT FORK
21. Measure:
lDistance a
Out of specification ® Turn into the
locknut.
Distance a:
20 mm (0.79 in) or more
Between damper rod 1 top and
locknut 2 top.
22. Loosen:
lRebound damping adjuster 1
NOTE:
lLoosen the rebound damping adjuster finger
tight.
lRecord the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
23. Install
lCushion rubber 1
lWasher 2
lSpacer 3
To cap bolt 4.
NOTE:
Install the cushion rubber with its smaller
dia.end a facing the cap bolt.
24. Install:
lPush rod 1
lFork spring 2
NOTE:
lInstall the fork spring with the damper rod 3
pulled up.
lAfter installing the fork spring, hold the
damper rod end so that it will not go down.
25. Install:
lCap bolt 1
Fully tighten the cap bolt onto the
damper rod by hand.

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CHASFRONT FORK
26. Tighten:
lCap bolt (locknut) 1
NOTE:
lWhile compressing the fork spring, set the
thin type spanners 2 between the spacer 3
and spring guide 4.
lHold the locknut 5 and tighten the cap bolt
with specified torque.
T R..29 Nm (2.9 m · kg, 21 ft · lb)
27. Install:
lCap bolt 1
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
28. Install:
lProtector guide 1
EC5552A0
Installation
1. Install:
lFront fork 1
NOTE:
lTemporarily tighten the pinch bolts (under
bracket).
lDo not tighten the pinch bolts (handle crown)
yet.
2. Tighten:
lCap bolt 1
3. Adjust:
lFront fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
T R..30 Nm (3.0 m · kg, 22 ft · lb)

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CHASFRONT FORK
4. Tighten:
lPinch bolt (handle crown) 1
lPinch bolt (under bracket) 2
ACHTUNG:CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
lBrake hose holder 1
lCaliper 2
lBolt (caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
6. Install:
lBrake hose holder 1
lBolt (brake hose holder) 2
lProtector 3
lBolt (protector) 4
NOTE:
When installing the brake hose holder, pass
the brake hose 5 in front of the axle boss a,
then fit it into the hose groove b so that the
brake hose does not contact the nut (wheel
axle).
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Adjust:
lRebound damping force
NOTE:
Turn in the damping adjuster 1 finger-tight
and then turn out to the originally set position.

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CHAS
EC560000
STEERING
Extent of removal:1 Under bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
Refer to “HANDLEBAR” section. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Number plate
Handlebar
Cable guide
Front fender
1 Steering shaft nut 1
2 Front fork 2 Refer to “FRONT FORK” section.
3 Handle crown 1
4 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
5 Under bracket 1
6 Ball race cover 1
7 Bearing (upper) 1
8 Bearing (lower) 1 Refer to “REMOVAL POINTS”.
9 Ball race 2 Refer to “REMOVAL POINTS”.
WARNING
Support the machine securely so there is nodanger of it falling over.
2
1
STEERING