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))
Drive chain related components
Drive chain
Engine sprocket
Rear sprocket
Dust seal
Bearing
Retainer
Sprocket mounting drum
Wheel damper
145 N·m (14.5 Kgf-m,
105.0 Lbf-ft)
60 N·m
(6.0 Kgf-m, 43.0 Lbf-ft)
Apply grease
Apply thread lock to
thread p ...
Washing the motorcycle
When washing the motorcycle,
follow the instructions below:
Remove dirt and mud from the
motorcycle with running water.
You may use a soft sponge or
brush. Do not use hard materials
which can scratch the
paint.
Wash the entire motorcycle
with a mild detergent or car
...
Gearshift shaft / gearshift cam plate removal
and installation
Removal
Remove the engine sprocket cover. Refer to “engine sprocket removal and
installation” in section 3a .
Remove the clutch components. Refer to “clutch removal” in section 5c .
Remove the snap ring (1) and washer (2) from the
gearshift shaft.
Special tool
: 09900–06 ...