RZV500R Flat-Rate Motorcycle Inspection Front Maintenance + OH Wheel Bearing Maintenance D.I.D ZVM-X & Sunstar Service Kit + Other

DSC08898
Day three: lately, original parts often don’t come in stock.
Measuring each component and learning about tolerances, materials, and manufacturers is really educational.
Manufacturers that organize everything by part number so you can assemble without thinking are truly impressive.

DSC08845
Back to the previous condition again—it’s already been cleaned and stored.

DSC08896
The manual lists 36φ, but this is a Yamaha-specific stepped fork, so the seal side is probably 37φ.
The inner tube dimensions vary quite a bit from top to bottom. While the seal contact area is critical, how smoothly it operates and how well we minimize seal damage really affects longevity.

DSC08895
No runout, so that’s reassuring.

DSC_3190
Lately I’ve been choosing Newtech synthetic fork oil.
With all those period-correct mechanisms like air braces and anti-dive, assembly is quite labor-intensive.

  • Copied the URL !