Toyota RAV4 manuals

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

  1. Remove the front wheel. Refer to front wheel assembly removal and installation in section 2d .
Caution

  •  make sure that the motorcycle is supported securely.
  •  Do not operate the front brake lever with the front wheel removed.
  1. Disconnect the brake hoses from the clamps on the front fender.
  2.  Remove the reflex reflectors (1). (Except for e-02, 19, 51)
  3.  remove the front fender (2) by removing the bolts

Suzuki GSX-R. Front fork removal and installation


Suzuki GSX-R. Front fork removal and installation


  1. Loosen the front fork upper clamp bolt (3).
  2. Loosen the handlebar clamp bolt (4).
Note

slightly loosen the front fork cap (5) to facilitate later disassembly.

Special tool : 0994153670 (front fork cap
socket wrench (45 mm))

Suzuki GSX-R. Front fork removal and installation


  1. 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.

Suzuki GSX-R. Front fork removal and installation


Installation

  1. Set the front fork to the steering stem lower bracket temporarily by tightening the lower clamp bolts (1).

Suzuki GSX-R. Front fork removal and installation


  1. Tighten the front fork cap (2) to the specified torque.

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

  1. Loosen the lower clamp bolts.
  2.  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.

Suzuki GSX-R. Front fork removal and installation


  1. 7.0 Mm (0.28 In)
  1. Tighten the front fork lower clamp bolts (1).

Tightening torque front fork lower clamp bolt (b): 23 nm (2.3 Kgfm, 16.5 Lbf-ft)

Suzuki GSX-R. Front fork removal and installation


  1. Tighten the front fork upper clamp bolt (3).

Tightening torque front fork upper clamp bolt (c): 23 nm (2.3 Kgfm, 16.5 Lbf-ft)

  1. Tighten the handlebar clamp bolt (4).

Tightening torque handlebar clamp bolt (d): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front fork removal and installation


  1. 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.

Suzuki GSX-R. Front fork removal and installation


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:

Starter relay inspection
Inspect the starter relay in the following procedures:  remove the starter relay. Refer to starter relay removal and installation .  Apply 12 v to a and b terminals and check for continuity between the positive and negative terminals using the multi-circuit tester. If th ...

DTC c62 (p0443): evap system purge control solenoid valve circuit malfunction (e-33 only)
Detected condition and possible cause Detected condition Possible cause Evap system purge control valve voltage is not input to ecm. Evap system purge control valve circuit open or short. Evap system purge control valve malfunction. Ecm malfunction. ...

Ignition system check
Remove the spark plugs and reattach them to the spark plug caps. Put the engine stop switch in the "" position and ignition switch in the "on" position. While holding a spark plug with its base firmly against the engine, push the electric starter butt ...

2011-2020 Copyright www.suzukigsxr.org