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

Removal

1. Remove the brake calipers, left and right.

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

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

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

Installation

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

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

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

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

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

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

Special tool (a): 09900–18740 (hexagon socket
(24 mm))

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

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

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

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

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

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