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))
Troubleshooting
This troubleshooting guide is provided
to help you find the cause of
some common complaints.
Caution
Failure to troubleshoot a problem
correctly can damage your
motorcycle. Improper repairs
or adjustments may damage
the motorcycle instead of fixing
it. Such damage may ...
Fuel tank construction
Fuel tank heat
shield
: aluminum film side should face the engine side.
Fuel tank front cover
Fuel tank front bracket
Velcro fastenings
: clean the adhesive surface before adhering
the velcro fastenings.
Insert
to the bracket.
Apply
...
Idle speed
Adjust the engine idle speed periodically on the engine at normal operating
temperature.
To adjust the idle speed:
Lift the fuel tank by referring to
the air cleaner section.
Start the engine and warm it
up by running at idling speed
for 10 minutes in summer
(where ambie ...