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

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

Disassembly

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

2. Loosen the front fork cap using the special tool and vise.

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

3. 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.

4. Remove the piston rod assembly (2).

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

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

7. Remove the dust seal (6).
8.  Remove the oil seal stopper ring (7).

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

10. Remove the slide bushing (8) from the inner tube.
11.  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)

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

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

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

Assembly

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)

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

4. Insert the inner tube into the outer tube.
5.  Press fit the guide bushing (5) using the special tools.
6.  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)

7. Install the stopper ring (2).

8. Press fit the dust seal (1).

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

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

11. 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)

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

13. Assemble the piston rod and rod guide case (10).
14.  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)

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

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

16. 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)

17. 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)

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

19. 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)

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

21. Tighten the front fork cap to the specified torque.

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))