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Suzuki GSX-R 1000 Service Manual: Front fork disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Suspension / Front suspension / Repair instructions / Front fork disassembly and assembly

Refer to “front fork removal and installation” (page 2b- 2).

Note

the right and left front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side.

Disassembly

  1. Turn the spring pre-load adjuster (1) to the softest position.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Loosen the front fork cap using the special tool and vise.
Caution

do not clamp the outer tube too tight.

Special tool (a): 09941–53670 (front fork cap socket wrench (45 mm))

Suzuki GSX-R. Front fork disassembly and assembly


  1. Loosen the rod guide case installed in the inner tube using the special tool.

Special tool (b): 09940–84710 (rod guide case
wrench)

Hold the
front fork cap when removing the rod guide case, or it will jump out due to the spring pressure.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Remove the piston rod assembly (2).

Suzuki GSX-R. Front fork disassembly and assembly


  1. Remove the spring collar b (3) and spring (4).


  1. Drain fork oil and remove the spring collar a (5).

Suzuki GSX-R. Front fork disassembly and assembly


  1. Remove the dust seal (6).
  2.  Remove the oil seal stopper ring (7).
Caution

  •  scratches on the inner tube could cause oil leaks.
  •  Avoid scratching when removing.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Pull out the inner tube from the outer tube.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Remove the slide bushing (8) from the inner tube.
  2.  Remove the following parts from the inner tube.
  1.  guide bushing (9)
  2.  oil seal spacer (10)
  3.  oil seal (11)
  4.  oil seal stopper ring (7)
  5.  dust seal (6)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Hold the piston rod assembly with the special tool and vise.

Special tool (a): 09941–53670 (front fork cap
socket wrench (45 mm))

  1. Loosen the piston rod nut (12) and disassemble the piston rod as shown.

Suzuki GSX-R. Front fork disassembly and assembly


Suzuki GSX-R. Front fork disassembly and assembly


Assembly

Caution

  •  clean all fork parts before reassembling.
  •  Replace the o-rings, seals and bushings with new ones.
  •  Apply specified front fork oil when installing the o-rings, slide bushing and guide bushing.
  1. Cover the inner tube with a plastic film.
  2.  Install the following parts to the inner tube.
  1. new dust seal (1)
  2.  stopper ring (2)
  3.  new oil seal (3)
Caution

  •  scratches on the oil seal lip may cause oil leakage. When installing the seals, place a plastic film over the slide bushing groove and edges of the inner tube to avoid damaging the seals’ lip.
  •  Misdirecting of the parts may cause inferior operation and oil leakage.
  •  Face the stamp mark side “a” of the oil seal to the dust seal side.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Stamp mark
  1. Remove the plastic film and install the oil seal spacer (4), guide bushing (5) and slide bushing (6) keep them free from dust.
Caution

  •  face the grooved side “b” of the oil seal spacer to the outer tube side.
  •  Position the slit “c” of slide bushing 90° against the traveling direction.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Groove
  2. Slit
  1. Insert the inner tube into the outer tube.
  2.  Press fit the guide bushing (5) using the special tools.
  3.  Press fit the new oil seal (3) using the special tools until the stopper ring groove on the outer tube can be seen.

Special tool (a): 09940–52861 (front fork oil
seal installer set)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Install the stopper ring (2).
Caution

make sure that the stopper ring is fitted securely into the groove.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Press fit the dust seal (1).

Suzuki GSX-R. Front fork disassembly and assembly


  1. Insert the spring collar a (7) and spring (8) into the inner tube.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Insert the spring collar b (9) into the inner tube.
Caution

face the flange “d” of the collar to the spring side.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Flange
  1. Pour specified fork oil until its surface passes the side holes of inner tube.

: Fork oil 99000–99001–ss5
(suzuki fork oil ss-05 or equivalent)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Slowly stroke the outer tube more than ten times to pump out air.
Note

take extreme attention to pump out air completely.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Assemble the piston rod and rod guide case (10).
  2.  Tighten the piston rod nut (11) with the special tool and vise.

Tightening torque piston rod nut (a): 28 n·m (2.8 Kgf-m, 20.0 Lbf-ft)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Insert the piston rod assembly into the inner tube and temporarily tighten the rod guide case by hand.
Caution

insert the piston rod assembly into the inner tube with the outer tube lifted up. Be sure not to damage the piston ring (12) of the rod guide case.

Special tool (b): 09940–84710 (rod guide case
wrench)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Tighten the rod guide case to the specified torque.

    Refer to “rod guide case tightening torque” .

Special tool (b): 09940–84710 (rod guide case
wrench)

Tightening torque rod guide case: 90 n·m (9.0 Kgf-m, 65.0 Lbf-ft)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Pour specified fork oil up to the top of the rod guide case.

: Fork oil
99000–99001–ss5 (suzuki fork oil ss-05 or equivalent)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Push the front fork cap, then stroke the outer tube several times to pump out air.
Note

take extreme attention to pump out the air completely.

Suzuki GSX-R. Front fork disassembly and assembly


  1. Hold the front fork vertically and adjust the oil level using the special tool.

Special tool (c): 09943–74111 (front fork oil
level gauge)

Fork oil level “a” 75.0 Mm (2.95 In)

Suzuki GSX-R. Front fork disassembly and assembly


  1. Apply fork oil to the o-ring (13).
Caution

use new o-ring to prevent oil leakage.
  1. Tighten the front fork cap to the specified torque.
Caution

do not clamp the outer tube too tight.

Tightening torque front fork cap: 35 n·m (3.5 Kgf-m, 25.5 Lbf-ft)

Special tool (a): 09941–53670 (front fork cap
socket wrench (45 mm))

Suzuki GSX-R. Front fork disassembly and assembly


Front suspension adjustment
After installing the front fork, adjust the spring pre-load and two kinds of damping force as follows: Adjust the left and right front forks to the same setting. Spring pre-load ...

Front fork parts inspection
Refer to “front fork disassembly and assembly” . Inner and outer tubes Inspect the inner tube and outer tube for scratches Slide bushing / guide bushing Inspect the slide bushing and guide bus ...

Other materials:

Thermostat removal and installation
Removal Drain a small amount of engine coolant. Refer to “cooling system inspection” in section 0b .  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Remove the thermostat cover (1). Remove the thermostat ( ...

Starter motor inspection
Refer to “starter motor disassembly and assembly” . Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length “a” of the carbon brushes using a v ...

Engine coolant
Coolant level The engine coolant solution should be between "f" (full) and "1..:' (Low) level lines on the engine coolant reservoir. If the level is lower than "1..:' (Low) level line, bring it up to "f" (full) level by adding 50:50 mixture of distilled water ...

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