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Suzuki GSX-R 1000 Service Manual: Front wheel assembly removal and installation

Suzuki GSX-R 1000 Service Manual / Suspension / Wheels and tires / Repair instructions / Front wheel assembly removal and installation

Removal

  1. Remove the brake calipers, left and right.
Caution

do not operate the brake lever with the caliper removed.

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Loosen two axle pinch bolts (1) on the right front fork leg.
  2.  Remove the front axle bolt (2).

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.
Caution

do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycle with the exhaust pipes. Make sure that the motorcycle is supported securely.

  1. Loosen two axle pinch bolts (3) on the left front fork leg.
  2.  Draw out the front axle (4) and remove the front wheel.
  3. Remove the collar (5) (rh only).
Note

after removing the front wheel, fit the calipers temporarily to the original positions.

Suzuki GSX-R. Front wheel assembly removal and installation


Installation

  1. Install the collar (1) to the right side of the wheel.

Suzuki GSX-R. Front wheel assembly removal and installation


The directional
arrow on the tire should point to the wheel rotation.

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Insert the front axle from the left side and tighten the front axle bolt temporarily.
  2.  Tighten the brake caliper mounting bolts (2) to the specified torque.

Tightening torque front brake caliper mounting bolt (a): 39 nm ( 3.9 Kgf-m, 28.0 Lbf-ft)

After remounting
the brake calipers, pump the brake lever until the pistons push the pads correctly.

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Hold the front axle with the special tool and tighten the front axle bolt (3) to the specified torque.

Special tool (a): 0990018740 (hexagon socket
(24 mm))

Tightening torque front axle bolt (b): 100 nm (10.0 Kgf-m, 72.5 Lbfft)

  1. Tighten two axle pinch bolts (4) on the right fork leg to the specified torque.

Tightening torque front axle pinch bolt (c): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Move the front forks up and down 4 or 5 times

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Tighten two axle pinch bolts (5) on the left front fork leg to the specified torque.

Tightening torque front axle pinch bolt (d): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front wheel assembly removal and installation


Front wheel assembly construction
Brake disc bolt Brake caliper mounting bolt Front axle bolt Front axle pinch bolt Clearance 18 Nm (1.8 Kgf-m, 13.0 Lbf-ft) 39 Nm (3.9 Kgf-m ...

Front wheel related parts inspection
Refer to front wheel assembly removal and installation . Tire Refer to tire inspection in section 0b . Front brake disc Refer to front brake disc inspection in section 4b . Dust seal ...

Other materials:

Fuel line inspection
Inspect fuel line every 6 000 km (4 000 miles, 12 months) Inspect the fuel line in the following procedures:  lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).  Inspect the fuel feed hose (1) for damage and fuel leakage. ...

Tp sensor adjustment
Inspect the tp sensor setting position and adjust it if necessary in the following procedures:  connect the special tool (mode select switch) to the dealer mode coupler. Refer to self-diagnostic procedures in section 1a . Special tool : 0993082720 (mode selection switch) Warn ...

Left handlebar
Clutch lever 1 The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting the transmission gear. Squeezing the lever disengages the clutch. Headlight flasher switch 2 Press the switch to light the headlight. Dimmer switch 3 " " ...

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