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

Removal

1. Remove the front wheel. Refer to “front wheel assembly removal and installation” in section 2d .

2. Disconnect the brake hoses from the clamps on the front fender.
3.  Remove the reflex reflectors (1). (Except for e-02, 19, 51)
4.  remove the front fender (2) by removing the bolts

5. Loosen the front fork upper clamp bolt (3).
6. Loosen the handlebar clamp bolt (4).

Special tool : 09941–53670 (front fork cap
socket wrench (45 mm))

7. Loosen the front fork lower clamp bolts (6) and remove the front fork.

Installation

1. Set the front fork to the steering stem lower bracket temporarily by tightening the lower clamp bolts (1).

2. Tighten the front fork cap (2) to the specified torque.

Tightening torque front fork cap (a): 35 n·m (3.5 Kgf-m, 25.5 Lbf-ft)

3. Loosen the lower clamp bolts.
4.  Set the front fork with the edge of the outer tube positioned 7.0 Mm (0.28 In) “a” from the upper surface of the upper bracket.

5. Tighten the front fork lower clamp bolts (1).

Tightening torque front fork lower clamp bolt (b): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)

6. Tighten the front fork upper clamp bolt (3).

Tightening torque front fork upper clamp bolt (c): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)

7. Tighten the handlebar clamp bolt (4).

Tightening torque handlebar clamp bolt (d): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

8. Install the front wheel. Refer to “front wheel assembly removal and installation” in section 2d .

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