Inspectionanddisassembly

_{TIREINSPECTION:c::r6-68}

•Removethebrakedisc.

BRAKEDISCINSPECTION:c::r6-58

-Continuedonnextpage-^-

•Removebothsidedustsealsbyusingtheoilsealremover.

t+&Ri09913-50121:Oilsealremover

IACAUTIONI

Theremoveddustsealsmustbereplacedwithnewones.

AXLESHAFT

Usingadialgauge,checktheaxleshaftforrunoutandreplaceitiftherunoutexceedsthelimit.

tMili09900-20606:Dialgauge(1/100)

09900-20701:Magneticstand

09900-21304:V-blockset(100mm)

~Axleshaftrunout

ServiceLimit:0.25mm(0.010in)

WHEEL

Makesurethatthewheelrunoutcheckedasshowndoesnotexceedtheservicelimit.Anexcessiverunoutisusuallyduetowornorloosenedwheelbearingsandcanbereducedbyre•placingthebearings.Ifbearingreplacementfailstoreducetherunout,replacethewheel.

gWheelrunout

ServiceLimit(AxialandRadial):2.0mm(0.08in)

WHEELBEARINGS

Inspecttheplayofthewheelbearingsbyfingerwhiletheyareinthewheel.Rotatetheinnerracebyfingertoinspectforabnormalnoiseandsmoothrotation.

Replacethebearinginthefollowingprocedureifthereisany•

thingunusual.

•Removethewheelbearingsbyusingthespecialtool.

~09921-20220:Bearingremoverset

IACAUTIONI

Theremovedbearingsshouldbereplacedwithnewones.

REASSEMBLYANDREMOUNTING

Reassembleandremountthefrontwheelinthereverseorderofremovalanddisassembly.Payattentiontothefollowingpoints:

Left~c:::)Right

(!)25N·m

^{(2.5kgf·m,18.1lb-ft)2}5N·m

(2.5kgf-m,18.1lb-ft)

(!)23N·m

(2.3kgt·m,16.5lb-tt)

_,..,

_ao~

_V

^\-l~100Nm

_{(10.0kgf·m,72.5lb-ft)}

L-'23N·m

(2.3kgf·m,16.5lb-ft)

-

WHEELBEARING

•Applygreasetothewheelbearings.

~99000-25010:SUZUKISUPERGREASE"A"

•Installthewheelbearingsasfollowsbyusingthespecialtools.

QE09941-34513:Bearing/Steeringraceinstallerset

IACAUTIONI

Firstinstalltheleftwheelbearing,theninstalltherightwheelbearing.

Thesealedcoverofthebearingmustfaceoutside.

_Left¢::J^{¢RightLett¢::Jc::)>Right}

_Spacer

BRAKEDISC

Makesurethatthebrakedisciscleanandfreeofanygreasymatter.

•ApplyTHREADLOCKSUPER"1360"tothediscmountingboltsandtightenthemtothespecifiedtorque.

~Brakediscbolt(Front):23N·m(2.3kgf·m,16.5lb-ft)

~99000-32130:THREADLOCKSUPER"1360"

SPACERNUT

Aftertouchingtheflangeofspacernutbeingcontactwiththeleftfrontforkleg,tightenthetwoaxlepinchboltsontheleftfrontforklegtothespecifiedtorque.

(!)Frontaxlepinchbolt:23N·m(2.3kgf·m,16.5lb-ft)

WHEEL

Installthefrontwheelwiththefrontaxleandhand-tightenthefrontaxletemporarily.

AWARNING

Thedirectionalarrowonthetireshouldpointtothewheelrotation,whenremountingthewheel.

BRAKECALIPER

•Tightenthebrakecalipermountingboltstothespecifiedtorque.

(!)Frontbrakecalipermountingbolt:25N·m

_{(2.5kgf·m,18.1lb-ft)}

NOTE:

Pushthepistonsallthewayintothecaliperandremountthecalipers.

_-

^FRONTAXLE

•Tightenthefrontaxletothespecifiedtorque.(!)Frontaxle:100N·m(10.0kgf·m,72.5lb-ft)

NOTE:

Beforetighteningthetwoaxlepinchboltsontherightfrontforkleg,movethefrontforkupanddown4or5times.

•Tightentwoaxlepinchboltsontherightfrontforklegtothespecifiedtorque.

(!)Frontaxlepinchbolt:23N·m(2.3kgf·m,16.5lb-ft)

FRONTFORK

_CONSTRUCTION

L_

DO-ring

~1Springadj~ster

~Springretainer

~.Washer

_~'Spacer

t

61Spring.Rebounddampingforcead!uster

"IDInnerrod/damperrod(cartridge)

9,iInnertube

~1Anti-frictionmetal

_{•1].IProtecter}

,zDustseal

^{i1011sealstoppernng}

©Oilseal

~1Oilsealretainer

_{@Anti-frictionmetal}

\tiOillockpiece

1§iOutertube

A!Frontforkcapbolt

L

~'Innerrodlocknut

,.~Damperrodboll

l}iFrontaxlepinchbolt

E•Compressiondamping

^8-@)

^L__

forceadjuster_

ITEM ®	N·m 35	kgf·m 3.5	lb-ft 25.5
®	20	2.0	14.5
©	35	3.5	25.5
(D)	23	2.3	16.5
~	18	1.8	13.0

REMOVALANDDISASSEMBLY

•Removethefrontwheel.(c:::?'6-8)

•Disconnectthebrakehoses.

•Removethefrontfender.

•LoosenthefrontforkupperclampboltG).

NOTE:

Slightlyloosenthefrontforkcapbolts(2)beforelooseningthelowerclampboltstofacilitatelaterdisassembly.

•Loosenthehandlebarclampbolt@.

•Removethehandlebarsetbolt@.

NOTE:

Placetheragsundereachhandlebartopreventscratchingtheupperfairingandtheairintakepipes.

•Loosenthefrontforksetbolts.

NOTE:

Becarefulnottodropthefrontforkwhenlooseningthebolts.

•RemovetheprotectertID.

•Loosenthefrontforkcapbolt(j)andremovethespringseat

~.

•Removethefrontforkcapboltwithspringadjusterbyholdingtheinnerrodlocknut.

•RemovethespacerQ),washers©,andspring@.

•Inverttheforkandstrokeitseveraltimestodrainoutforkoil.

_{•Holdtheforkinvertedforafewminutestodrainoil.}

_.....

•Removethedustseal.

•Removetheoilsealstopperring.

•Removethedamperrodbolt.

•Removethedamperrod.

•Extracttheoutertubefromtheinnertube.

NOTE:

Becarefulnottodamagetheinnertube.

IACAUTIONI

Theslidemetals,oilsealanddustsealmustbereplacedwithnewoneswhenreassemblingthefrontfork.

•Removethefollowingparts.

3)Oilseal

.2)Oilsealretainer

~~Anti-frictionmetal(Outertube)

·~Anti-frictionmetal(Innertube)

:IDOillockpiece

•Removethecompressiondampingforceadjuster.

NOTE:

Neverdisassemblethecompressiondampingforceadjuster.

DAMPERRODDISASSEMBLY

•LoosentheinnerrodlocknutCD.

•Removethespringadjuster.

IACAUTIONI

IReplacethe0-ringswithnewones.