Question about 1994 Yamaha FZR 600

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How do u disassemble forks - 1994 Yamaha FZR 600

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Here is a diagram of your forks:
http://216.37.204.203/Yamaha_OEM/YamahaMC.asp?Type=13&A=140&B=28
Assuming you have already removed your fork cap, you will need to remove the clip # 5 and the bolt # 18 then in a slide hammer type action, pull the upper tube out of the lower tube. There is a washer underneath the fork seal that will pull the fork seal out with the upper tube, so you have to compress the fork tube, then give it a good yank to pull the seal and separate the tubes.

A couple of tips here. First, to loosen the fork cap, loosen the top triple tree pinch bolt at each fork leg before removing the forks from the bike, then loosen the fork cap. You don't have to take the cap off at this time, but break it loose. It is very difficult to hold the fork tube and prevent it from turning once the fork is off the bike and out of the clamp. It is much easier to break it loose and leave it finger tight before dropping the forks out of the triple clamps. The key thing to remember is loosen the pinch bolt before attempting to loosen the cap. The pinch bolt applies extra pressure to the cap and can complicate the process of loosening the cap if left tight.
The other tip would be to use a 3/8" air impact wrench to loosen the allen bolt in the bottom of the fork leg. The internals will want to spin if you try to do it by hand.

Posted on Oct 05, 2009

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