Suzuki GSX-R 1000 Service Manual: 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 bushing for wear or damage. If they are worn or damaged, replace them with new ones. If they are not clean, clean them with a nylon brush and fork oil.
Fork spring
Measure the fork spring free length “a”. If it is shorter than the service limit, replace it with a new one.
Front fork spring free length “a” service limit: 236 mm (9.29 In)
Piston rod / piston ring
Inspect the piston rod and piston ring (1) for wear or damage. If any defects are found, replace the piston rod with a new one
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 t ...
Rod guide case tightening torque
Tighten the rod guide case in the following procedures:
measure the effective length l of the torque wrench.
Calculate the reading torque on the torque wrench by
use of the formula shown below.
...
Other materials:
Front brake caliper removal and installation
Note
the right and left calipers are installed
symmetrically and therefore the removal
procedure for one side is the same as that for
the other side.
Removal
Drain brake fluid. Refer to “brake fluid replacement” in section 4a .
Remove the brake hose from the cali ...
Specifications
Service data
Valve + guide
unit: mm (in)
Camshaft + cylinder head
unit: mm (in)
Cylinder + piston + piston ring
unit: mm (in)
Conrod + crankshaft
unit: mm (in)
Balancer
unit: mm (in)
Oil pump
Clutch
unit: mm (in)
Drive train
unit: mm (in) except ratio
...
Using the transmission
The transmission is provided to
keep the engine operating
smoothly in its normal operating
speed range. The gear ratios
have been carefully chosen to
meet the characteristics of the
engine. The rider should always
select the most suitable gear for
the prevailing conditions. Never
slip the c ...