Inspection

INNERANDOUTERTUBES

Inspecttheinnertubeslidingsurfaceandoutertubeslidingsur•

_{faceforscuffing.}

FORKSPRING

Measuretheforkspringfreelength.

Ifitisshorterthantheservicelimit,replaceitwithanewone.

l,'WFrontforkspringfreelength

Servicelimit:243mm(9.6in)

DAMPERROD

Movetheinnerrodbyhandtoexamineitforsmoothness.

~-

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REASSEMBLYANDREMOUNTING

Reassembleandremountthefrontforkinthereverseorderofremovalanddisassembly.Payattensiontothefollowingpoints:

COMPRESSIONDAMPINGFORCEADJUSTER

•Tightenthecompressiondampingforceadjustertothespeci•

fiedtorque.

(!)Compressiondampingforceadjuster:

_{18N·m(1.8kgf·m,13.0lb-ft)}

IACAUTIONI

Theremoved0-ringmustbereplacedwithanewone.

DAMPERROD

•Installtherebounddampingforceadjuster0)intothespringadjuster(?).

•Adjusttheheight®oftherebounddampingforceadjusterat

1.5mm(0.06in).

•Keeptheabovepositionandturnintherebounddampingforceadjusterfullyintotheinnerrod@.

•Tightentheinnerrodlocknut@tothespecifiedtorquebyholdingthespringadjuster.

~Innerrodlocknut:20N·m(2.0kgf·m,14.5lb-ft)

TUBEMETALSANDSEALS

•HoldtheinnertubeverticallyandcleanthemetalgrooveandinstalltheANTI-FRICTIONmetalbyhandasshown.

IACAUTIONI

Usespecialcaretopreventdamagetothe"Teflon"coatedsurfaceoftheAnti-frictioninnertubemetalwhenmount•ingit.

_t

^@1.5mm

(0.06in)

•Installtheoillockpiece®ontotheinnertube.

IACAUTIONI

...*Donotusesolventsforwashingtopreventoilseal

damage.

•ApplyforkoiltotheAnti-frictionmetals,lipofoilsealanddustseal.

•Applyforkoiltotheoilsealliplightlybeforeinstallingit.

E!!J99000-99001-SSS:SUZUKIFORKOILSS-08(#10)

•Installthefollowingpartsasshown.

rDOilseal

'£)Oilsealretainer

@Anti-frictionmetal(Outertube)

®Anti-frictionmetal(Innertube)(~Dustseal

^{IDOilsealstopperring}

•Inserttheinnertubeintotheoutertubeandfittheoilsealanddustsealwiththespecialtool.

1fciot109940-52861:Frontforkoilsealinstaller

DAMPERRODBOLT

•Tightenthedamperrodbolttothespecifiedtorque.(!)Damperrodbolt:35N·m(3.5kgf·m,25.5lb-ft)IACAUTIONI

Useanewdamperrodboltgaskettopreventoilleak•

age.

NOTE:

Ifthedamperrodturnswiththedamperrodbolt,temporarilyin•

stalltheforkspring.spacerandcapbolt.

@

@_,,-"D<

G)----\/1'1(2)

FORKOIL

•Placethefrontforkverticallywithoutspring.

•Compressitfully.

•Pourspecifiedfrontforkoiluptothetopleveloftheoutertube.

•Movetheinnerrodslowlymorethantentimesuntilbubblesdonotcomeoutfromtheoil.

NOTE:

Refillfrontforkoiluptothetopoftheoutertubetofindbubbleswhilebleedingair.

•Refillspecifiedfrontforkoiluptothetopleveloftheoutertubeagain.Movetheoutertubeupanddownseveralstrokesuntilbubblesdonotcomeoutfromtheoil.

•Keepthefrontforkverticallyandwait5-6minutes.

NOTE:

*Alwayskeepoilleveloverthecartridgetopend,orairmayenterthecartridgeduringthisprocedure.

;cTakeextreamattentiontopumpoutaircompletely.

•Holdthefrontforkverticallyandadjustforkoillevelwiththespecialtool.

NOTE:

Whenadjustingtheforkoillevel,removetheforkspringandcom•

presstheinnertubefully.

1r1i0ti09943-74111:Frontforkoillevelgauge

Forkoillevel:102mm(4.0in)Forkoiltype:SS-08(#10)

E5J99000-99001-SS8:SUZUKIFORKOILSS-08(#10)Capacity(eachleg):528ml(17.8/18.6US/Impoz)

FORKSPRING

•Installtheforkspring.

NOTE:

Thesmallend@oftheforkspringshouldbeatthebottomofthefrontfork.

FRONTFORKCAPBOLT

•InstallthewashersG)andspacer(2).

•Installthefrontforkcap.

•InstallthespringretainerQ).

•Applyforkoillightlytothe0-ring.

_IACAUTIONI

^{IUseanew0-ringtopreventoilleakage.}

•Tightenthefrontforkcapbolttemporarily.

•Installthefrontforkprotecter.

NOTE:

Fittheprojectionofthefrontforkprotectertothedepressionofthefrontforkoutertube.

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^L)-;·/®

•Settheuppersurfaceoftheinnertubeat6.3mm(0.25in)height®fromtheuppersurfaceofthesteeringstemupperbracketandtightenthefrontforklowerclampbolts11)tothe

specifiedtorque.

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

•Tightenthehandlebarsetbolt(2)tothespecifiedtorque.(!)Handlebarsetbolt:1ON·m(1.0kgf·m,7.0lb-ft)

•TightenthehandlebarclampboltQ).

•Tightenthefrontforkcapbolt@tothespecifiedtorqueandrecheckthefrontforkoutertubeuppersurfaceheight®fromtheuppersurfaceofthesteeringstemupperbracket.

(!)Handlebarclampbolt:23N·m(2.3kgf·m,16.5lb-ft)Frontforkcapbolt:35N·m(3.5kgf·m,25.5lb-ft)

•Tightenthefrontforkupperclampbolt®·

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

•Installthefrontfender.

•Installthefrontwheel.(c::::T6·11)

NOTE:

Beforetighteningthetwoaxlepinchboltsonrightfrontforkleg,movethefrontforkupanddown4or5times.

_{SUSPENSIONSETTING}

Afterinstallingthefrontfork,adjustthespringpre-loadanddamp• ingforceasfollows.
SPRINGPRE-LOADADJUSTMENT		,	2
Therearesevengroovedlinesonthesideofthespringadjuster.	11------3		4
Position1providesthemaximumspringpre-loadandposition7
providestheminimumspringpre-load.
(STDposition:4)

DAMPINGFORCEADJUSTMENT

{Reboundside)

FullyturnthedampingforceadjusterG)clockwise.Itisatstiffestpositionandturnitouttostandardsettingposition.

(STDposition:1and^1/sturnsout[Fine-tunetheadjusterbyturn•

ingitslightlyuntiltwopunchmarksalign.])

(Compressionside)

Fullyturnthedampingforceadjuster(?)clockwise.Itisatstiffestpositionandturnitouttostandardsettingposition.

(STDposition:1andYaturnsout[Fine-tunetheadjusterbyturn•

ingitslightlyuntiltwopunchmarksalign.])

_{STANDARDFRONTSUSPENSIONSETIING}

Reboundside

~

Soloriding

FRONT

Springpre-load^{DampingforceadjusteradjusterReboundC}ompression

Softer41andYaturnsout1and1/.turnsout

Standard41and1/sturnsout1and1/sturnsout

Stiffer41and^1/sturnsout1turnout

_{Compressionside}

_Dualriding41andYeturnsout1and1/sturnsout

AWARNING

Besuretoadjustthespringpre-loadanddampingforceonbothfrontforklegsequally.

STEERINGDAMPER

CONSTRUCTION

_{1Steeringdamper}

2Dustseal