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))
Engine components removable with the
engine in place
Engine components which can be removed while the engine is installed on the
frame are as follows. For the installing
and removing procedures, refer to respective paragraphs describing each
component.
Center of engine
Item
Removal
Inspection
Installation
...
Clutch cable removal and installation
Removal
Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the clutch cable from the clutch lever.
Refer to “handlebar removal and installation” in section 6b .
Remove the clutch cable as shown in the throttle cable ro ...
Ignition switch inspection
Inspect the ignition switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the ignition switch lead wire coupler (1).
Inspect the ignition switch for continuity with a tester.
If ...