Can anyone tell me the procedure for dismantling/servicing Yam TYZ forks.

Thanks

From memory...

At least loosen the allen bolt at the bottom of leg beform starting to dismantle as the spring tension should enable you to undo it without holding tools, especially if you have an air/electric ratchet. REMEMBER, the damping adjuster is inside the head of the allen bolt so screw it right in before inserting the allen key, otherwise you may damage the adjuster, it's only brass (bitter experience)

Undo the fork caps from the stanchions. The fork caps are screwed onto the internal damper rod and secured with a locknut underneath them. To remove the cap from the damper rod you need to hold the locknut with a spanner and undo the cap. Bit fiddly as the spring/preload spacer is in the way. You can then remove the spring and spacer etc. making a note of their fitted order.

Turn fork upside down and pump out oil, also pump the damper rod as this holds oil too.

Then remove the allen bolt from the bottom of the fork leg, hold the fork leg in one hand (or vice) and pull the stanchion sharply out. You probably need 2 or 3 goes to shock it free of the bushes. Watch that the damper rod doesn't disappear as it is now free, no longer held in place by the allen bolt. May be better to remove it before trying to shock the stanchion free.

Once the stanchion is out you can replace the seals and bushes, just note their order before sliding them off.

Reassembly is the reverse.

To fill with oil you need the leg upright with stanchion fully extended but no spring. Fill to the top with oil, then pump the damper rod 7 or 8 times through its full stroke to distribute the oil internally. Refill to the top and then pump the stanchion itself 7 or 8 times but not quite right through its full stroke to completely distribute all the oil. The oil level will fall again. You are looking for an air gap of 95mm (Birkett's recommendation to me) Add or remove oil as needed.

Refit spring/spacer and cap and screw cap back into stanchion.

Think that's it, been a long time so I may have overlooked something but I don't think so. Reset your damping adjuster back to original position.

Thanks very much!!!