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
- Remove the front wheel. Refer to “front wheel assembly removal and installation” in section 2d .
Caution
|
- Disconnect the brake hoses from the clamps on the front fender.
- Remove the reflex reflectors (1). (Except for e-02, 19, 51)
- remove the front fender (2) by removing the bolts
- Loosen the front fork upper clamp bolt (3).
- Loosen the handlebar clamp bolt (4).
| Note slightly loosen the front fork cap (5) to facilitate later disassembly. |
Special tool
: 09941–53670 (front fork cap
socket
wrench (45 mm))
- 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. |
Installation
- Set the front fork to the steering stem lower bracket temporarily by tightening the lower clamp bolts (1).
- 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)
- Loosen the lower clamp bolts.
- 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.
|
- 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)
- 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)
- Tighten the handlebar clamp bolt (4).
Tightening torque handlebar clamp bolt (d): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- 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. |
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:
Water pump components
Impeller
Mechanical seal
Oil seal
O-ring
O-ring
8
N·m (0.8 Kgf-n, 6.0 Ib-ft)
10 N·m
(1.0 Kgf-n, 7.0 Ib-ft)
6 N·m (0.6
Kgf-n, 4.5 Ib-ft)
13 N·m
(1.3 Kgf-n, 9.5 Ib-ft)
Apply grease.
Apply engine coolant.
Apply molyb ...
Specifications
Service data
Clutch
unit: mm (in)
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Clutch control system components” “clutch components”
Reference: for the tightening torque of fastener not specified in this ...
Battery current leakage inspection
Inspect the battery current leakage in the following
procedures:
turn the ignition switch off.
Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Disconnect the battery (–) lead wire.
Measure the current betwee ...