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

Note

the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.

Removal

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

  •  make sure that the motorcycle is supported securely.
  •  Do not operate the front brake lever with the front wheel removed.
  1. Disconnect the brake hoses from the clamps on the front fender.
  2.  Remove the reflex reflectors (1). (Except for e-02, 19, 51)
  3.  remove the front fender (2) by removing the bolts

Suzuki GSX-R. Front fork removal and installation


Suzuki GSX-R. Front fork removal and installation


  1. Loosen the front fork upper clamp bolt (3).
  2. Loosen the handlebar clamp bolt (4).
Note

slightly loosen the front fork cap (5) to facilitate later disassembly.

Special tool : 0994153670 (front fork cap
socket wrench (45 mm))

Suzuki GSX-R. Front fork removal and installation


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

hold the front fork by hand to prevent it sliding out of the steering stem.

Suzuki GSX-R. Front fork removal and installation


Installation

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

Suzuki GSX-R. Front fork removal and installation


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

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

  1. Loosen the lower clamp bolts.
  2.  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.

Suzuki GSX-R. Front fork removal and installation


  1. 7.0 Mm (0.28 In)
  1. Tighten the front fork lower clamp bolts (1).

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

Suzuki GSX-R. Front fork removal and installation


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

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

  1. Tighten the handlebar clamp bolt (4).

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

Suzuki GSX-R. Front fork removal and installation


  1. 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.

 

Note

before tightening the front axle bolt and front axle pinch bolts, move the front fork up and down four or five times.

Suzuki GSX-R. Front fork removal and installation


Front fork components
Front fork cap O-ring Rebound damping force adjuster rod Compression damping force adjuster rod Piston rod nut O-ring Piston ring Rod guide case Spr ...

Front suspension adjustment
After installing the front fork, adjust the spring pre-load and two kinds of damping force as follows: Adjust the left and right front forks to the same setting. Spring pre-load ...

Other materials:

Brake fluid
Check the brake fluid level in both front and rear brake fluid reservoirs. If the level in either reservoir is below the lower mark, inspect for brake pad wear and leaks. Warning Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or ...

Short circuit check (wire harness to ground)
Disconnect the negative () cable from the battery.  Disconnect the connectors/couplers at both ends of the circuit to be checked. Note if the circuit to be checked branches to other parts as shown, disconnect all connectors/ couplers of those parts. Otherwise, diagnos ...

Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:  remove the fuel mesh filter. Refer to fuel pump disassembly and assembly .  If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power. Such a filter ...

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