Suzuki GSX-R 1000 Service Manual: Front fork parts inspection

Suzuki GSX-R 1000 Service Manual / Suspension / Front suspension / Repair instructions / Front fork parts inspection

Refer to “front fork disassembly and assembly” .

Inner and outer tubes

Inspect the inner tube and outer tube for scratches

Suzuki GSX-R. Inner and outer tubes

Slide bushing / guide bushing

Inspect the slide bushing and guide bushing for wear or damage. If they are worn or damaged, replace them with new ones. If they are not clean, clean them with a nylon brush and fork oil.

Suzuki GSX-R. Slide bushing / guide bushing

Fork spring

Measure the fork spring free length “a”. If it is shorter than the service limit, replace it with a new one.

Front fork spring free length “a” service limit: 236 mm (9.29 In)

Suzuki GSX-R. Fork spring

Piston rod / piston ring

Inspect the piston rod and piston ring (1) for wear or damage. If any defects are found, replace the piston rod with a new one

Suzuki GSX-R. Piston rod / piston ring

Front fork disassembly and assembly

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 t ...

Rod guide case tightening torque

Tighten the rod guide case in the following procedures: measure the effective length l of the torque wrench. Calculate the reading torque on the torque wrench by use of the formula shown below. ...

Other materials:

Water pump removal and installation
Removal Note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, visually inspect the mechanical seal and s ...

Ignition switch
The ignitionr switch has 4 positions: "Off" position All electrical circuits are cut off. The engine will not start. The key can be removed. "On" position The ignition circuit is completed and the engine can run. The headlight and taillight will automatically turn ...

Front brake components
Seal set Piston and seal set Brake pad spring Brake pad set Front brake disc 7.5 N·m (0.75 Kgf-m, 5.5 Lbf-ft) 15 N·m (1.5 Kgf-m, 11.0 Lbf-ft) 39 N·m (3.9 Kgf-m, 28.0 Lbf-ft) 18 N·m (1.8 Kgf-m, 13.0 Lbf-ft) Apply thread lo ...