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
Caution do not clamp the outer tube too tight. |
Special tool (a): 09941–53670 (front fork cap socket wrench (45 mm))
Special tool
(b): 09940–84710 (rod guide case
wrench)
![]() front fork cap when removing the rod guide case, or it will jump out due to the spring pressure. |
Caution
|
Special tool
(a): 09941–53670 (front fork cap
socket
wrench (45 mm))
Assembly
Caution
|
Caution
|
|
Caution
|
|
Special tool
(a): 09940–52861 (front fork oil
seal
installer set)
Caution make sure that the stopper ring is fitted securely into the groove. |
Caution face the flange “d” of the collar to the spring side. |
|
: Fork oil 99000–99001–ss5
(suzuki
fork oil ss-05 or equivalent)
Note take extreme attention to pump out air completely. |
Tightening torque piston rod nut (a): 28 n·m (2.8 Kgf-m, 20.0 Lbf-ft)
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)
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)
: Fork oil
99000–99001–ss5 (suzuki
fork oil ss-05 or equivalent)
Note take extreme attention to pump out the air completely. |
Special tool
(c): 09943–74111 (front fork oil
level
gauge)
Fork oil level “a” 75.0 Mm (2.95 In)
Caution use new o-ring to prevent oil leakage. |
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))
Gearshift lever construction
Gearshift lever bracket
Gearshift lever shaft
Washer
Snap ring
Gearshift lever
Footrest top surface
65 – 75 Mm (2.6 – 3.0 In)
28 N·m (2.8 Kgf-m,
20.0 Lbf-ft)
40 N·m
(4.0 Kgf-m, 29.0 Lbf-ft)
Apply grease.
Grease.
...
Headlight bulb and position light bulb
replacement
Caution
when you touch the bulb with your bare
hands, clean the bulb with a cloth moistened
with alcohol or soap water to prevent
premature bulb failure.
Low beam bulb
Remove the combination meter. Refer to “combination meter removal and
installation” in section 9c .
...
Most accidents can be avoided
The most common type of motorcycle
accident in the u.S. Occurs
when a car traveling towards a
motorcycle turns left in front of the
motorcycle. Is that because other
drivers are out to get motorcyclists?
No. Other drivers simply
don't always notice motorcyclists.
Ride defensively. Wise mot ...