09940-14960:Steeringstemnutwrenchsocket

•Drawoutthesteeringstemlowerbracket.

NOTE:

Holdthesteeringstemlowerbracketbyhandtopreventitfromfalling.

•RemovethedustsealG),thesteeringstemupperbearingin•

nerrace·~andthebearing@.

Inspectionanddisassembly

Inspecttheremovedpartsforthefollowingabnormalities.

*Handlebarsdistortion

•Racewearandbrinelling

•Bearingwearordamage

*Abnormalnoiseofbearing

Ifanyabnormalpointsarefound,replacedefectivepartswiththenewones.

•Removethesteeringstemlowerbearinginnerracewithachisel.

IACAUTIONI

Theremovedbearingouterracemustbereplacedwithanewone.

•Driveoutthesteeringstembearingouterraces,upperandlower,usingasuitablewedgebar.

ACAUTIONI

Theremovedbearingouterracemustbereplacedwithanewone.

REASSEMBLYANDREMOUNTING

Reassembleandremountthesteeringsteminthereverseorderofremovalanddisassembly.

Payattentiontothefollowingpoints:OUTERRACE

^{•Pressintheupperandlowerbearingouterraceswiththespe•}

cialtools.

!T'OOtl09941-34513:Steeringouterraceinstallerset

INNERRACE

•Pressinthelowerbearinginnerracewiththespecialtool.

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·.~

....1~)

BEARING

•Applygreasetothebearingsandbearingraces.

~99000-25010:SUZUKISUPERGREASE"A"

•Installthelowerbearingtothesteeringstemlowerbracket.

•Installtheupperbearingandbearinginnerrace.

STEMNUT

•Installthedustseal.

•Tightenthesteeringstemnuttothespecifiedtorquewiththespecialtools.

!r'OOt!09940-14911:Steeringstemnutwrench

09940-14960:Steeringstemnutwrenchsocket

_{(!)Steeringstemnut:45N·m(4.5kgf·m,32.5lb-ft)}

•Turnthesteeringstemlowerbracketaboutfiveorsixtimestotheleftandrightsothattheangularballbearingswillbeseatedproperly.

•Loosenthestemnutby1/4-1/2turn.

NOTE:

Thisadjustmentwillvaryfrommotorcycletomotorcycle.

NOTE:

Wheninstallingthewasher,alignthestopperlugtothegrooveofthesteeringstem.

•Tightenthesteeringstemlocknuttothespecifiedtorquewiththespecialtools.

1R)bt109940-14911:Steeringstemnutwrench

09940-14960:Steeringstemnutwrenchsocket

(!)Steeringstemlocknut:80N·m(8.0kgf·m,58.0lb-ft)

....'

FRONTFORKANDSTEERINGSTEMUPPERBRACKETInstallthefrontforkandsteeringstemupperbracketfollowingsteps:

^{1)Installtheupperbracket,washer(Dandsteeringstemhead}

nut.Z)temporarily.

2)Setthefrontforksandtightenthesteeringstemheadnut(2).

~Steeringstemheadnut:90N·m(9.0kgf·m,65lb-ft)

3)Tightenthefrontforkupperandlowerclampbolts.(c:::::;r6·22)

•Installthehandlebars.(c:::::;r6-31)

•Installthefrontwheel.(c:::::;r6-10)

•Installthesteeringdamper.(c:::::/6-24)

STEERINGTENSIONADJUSTMENT

Checkthesteeringmovementinthefollowingprocedure.

•Bysupportingthemotorcyclewithajack,liftthefrontwheeluntilitisoffthefloorby20-30mm(0.8-1.2in).

•Removethesteeringdamper.(c::::r6-24)

•Checktomakesurethatthecablesandwireharnessesareproperlyrouted.

•Withthefrontwheelinthestraightaheadstate,hitchthespringscale(specialtool)ononehandlebargripendasshowninthe

^{figureandreadthegraduationwhenthehandlebarstartsmov•}

ing.Dothesameontheothergripend.

~Initialforce:200-500grams

!.foot!09940-92720:Springscale

•Iftheinitialforcereadonthescalewhenthehandlebarstartsturningiseithertooheavyortoolight,adjustittillitsatisfiesthespecification.

1)First,loosenthefrontforkupperandlowerclampbolts.steer•

ingstemheadnutandsteeringstemlocknut,andthenadjustthesteeringstemnutbylooseningortighteningit.

2)Tightenthesteeringstemlocknut,stemheadnutandfrontforkupperandlowerclampboltstothespecifiedtorqueandre-checktheinitialforcewiththespringscaleaccordingtothepreviouslydescribedprocedure.

3)Iftheinitialforceisfoundwithinthespecifiedrange,adjust-

menthasbeencompleted.

NOTE:

Holdthefrontforklegs,movethembackandforthandmakesurethatthesteeringisnotloose.

HANDLEBAR

_CONSTRUCTION

LetthandlegripRighthandlegnpRighthandleswitchLefthandleswitchhandlebar

Handlebalancer

AHandlebarclampbolt

§Handlebarsetbolt

REMOVALANDDISASSEMBLY

RIGHTHANDLEBAR

•RemovethebrakemastercylinderG).(c:76-59)

•Removetherighthandleswitch~-

•Removethehandlebalancer®·

•Removetherighthandlegrip@.

LEFTHANDLEBAR

•RemovetheclutchleverholderG).

•Removethelefthandleswitch<2).

•RemovethehandlebalancerQ).

•Removethelefthandlegrip@.