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

Suzuki GSX-R 1000 Service Manual / Suspension / Wheels and tires / Repair instructions / Front wheel assembly removal and installation

Removal

  1. Remove the brake calipers, left and right.
Caution

do not operate the brake lever with the caliper removed.

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Loosen two axle pinch bolts (1) on the right front fork leg.
  2.  Remove the front axle bolt (2).

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.
Caution

do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycle with the exhaust pipes. Make sure that the motorcycle is supported securely.

  1. Loosen two axle pinch bolts (3) on the left front fork leg.
  2.  Draw out the front axle (4) and remove the front wheel.
  3. Remove the collar (5) (rh only).
Note

after removing the front wheel, fit the calipers temporarily to the original positions.

Suzuki GSX-R. Front wheel assembly removal and installation


Installation

  1. Install the collar (1) to the right side of the wheel.

Suzuki GSX-R. Front wheel assembly removal and installation


The directional
arrow on the tire should point to the wheel rotation.

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Insert the front axle from the left side and tighten the front axle bolt temporarily.
  2.  Tighten the brake caliper mounting bolts (2) to the specified torque.

Tightening torque front brake caliper mounting bolt (a): 39 nm ( 3.9 Kgf-m, 28.0 Lbf-ft)

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

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Hold the front axle with the special tool and tighten the front axle bolt (3) to the specified torque.

Special tool (a): 0990018740 (hexagon socket
(24 mm))

Tightening torque front axle bolt (b): 100 nm (10.0 Kgf-m, 72.5 Lbfft)

  1. Tighten two axle pinch bolts (4) on the right fork leg to the specified torque.

Tightening torque front axle pinch bolt (c): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Move the front forks up and down 4 or 5 times

Suzuki GSX-R. Front wheel assembly removal and installation


  1. Tighten two axle pinch bolts (5) on the left front fork leg to the specified torque.

Tightening torque front axle pinch bolt (d): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front wheel assembly removal and installation


Front wheel assembly construction
Brake disc bolt Brake caliper mounting bolt Front axle bolt Front axle pinch bolt Clearance 18 Nm (1.8 Kgf-m, 13.0 Lbf-ft) 39 Nm (3.9 Kgf-m ...

Front wheel related parts inspection
Refer to front wheel assembly removal and installation . Tire Refer to tire inspection in section 0b . Front brake disc Refer to front brake disc inspection in section 4b . Dust seal ...

Other materials:

Rear turn signal light bulb replacement
Caution when you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. Remove the rear turn signal light lens (1). Replace the bulb (2). Reinstall the removed parts ...

Clutch cable play inspection and adjustment
Inspect clutch cable play every 6 000 km (4 000 miles, 12 months) Inspect and adjust the clutch cable play a as follows. Clutch cable play a 10 15 mm (0.4 0.6 In) Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).   ...

Tightening torque specifications
Note the specified tightening torque is described in the following. Throttle cable routing diagram  throttle body components  throttle body construction  engine assembly installation Reference: for the tightening torque of fastener not specified i ...

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