Suzuki GSX-R 1000 Service Manual: Front fork removal and installation
| Note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. |
Removal
- Remove the front wheel. Refer to “front wheel assembly removal and installation” in section 2d .
Caution
|
- Disconnect the brake hoses from the clamps on the front fender.
- Remove the reflex reflectors (1). (Except for e-02, 19, 51)
- remove the front fender (2) by removing the bolts
- Loosen the front fork upper clamp bolt (3).
- Loosen the handlebar clamp bolt (4).
| Note slightly loosen the front fork cap (5) to facilitate later disassembly. |
Special tool
: 09941–53670 (front fork cap
socket
wrench (45 mm))
- Loosen the front fork lower clamp bolts (6) and remove the front fork.
| Note hold the front fork by hand to prevent it sliding out of the steering stem. |
Installation
- Set the front fork to the steering stem lower bracket temporarily by tightening the lower clamp bolts (1).
- Tighten the front fork cap (2) to the specified torque.
Tightening torque front fork cap (a): 35 n·m (3.5 Kgf-m, 25.5 Lbf-ft)
- Loosen the lower clamp bolts.
- Set the front fork with the edge of the outer tube positioned 7.0 Mm (0.28 In) “a” from the upper surface of the upper bracket.
|
- Tighten the front fork lower clamp bolts (1).
Tightening torque front fork lower clamp bolt (b): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)
- Tighten the front fork upper clamp bolt (3).
Tightening torque front fork upper clamp bolt (c): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)
- Tighten the handlebar clamp bolt (4).
Tightening torque handlebar clamp bolt (d): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- Install the front wheel. Refer to “front wheel assembly removal and installation” in section 2d .
 After
remounting the brake calipers, pump the brake lever until the pistons push the pads correctly. |
| Note before tightening the front axle bolt and front axle pinch bolts, move the front fork up and down four or five times. |
Front fork components
Front fork cap
O-ring
Rebound damping force adjuster rod
Compression damping force adjuster rod
Piston rod nut
O-ring
Piston ring
Rod guide case
Spr ...
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 ...
Other materials:
Front brake caliper parts inspection
Refer to “front brake caliper disassembly and assembly” .
Brake caliper cylinder
Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any damage is found,
replace the caliper with a new one.
Brake caliper piston
Inspect the surface of brake caliper pistons for a ...
Starting the engine
Before attempting to start the
engine, make sure:
The transmission is in neutral.
The engine stop switch is in
the "" position.
Note: this motorcycle has a
starter interlock system for the
ignition and starter circuit. The
engine can only be started if:
...
Radiator / cooling fan motor removal and
installation
Removal
Remove the inner under cowlings. Refer to “exterior parts removal and
installation” in section 9d .
Drain engine coolant. Refer to “cooling system inspection” in section
0b .
Disconnect the reservoir tank inlet hose (1) and
water air bleed hose (2).
Remove ...