Inspectionanddisassembly

SPACER

•Removethespacersfromswingarm.

•Removethespacersfromthecushionlever.

•Inspectthespacersforanyflawsorotherdamage.Ifanyde•

fectsarefound,replacethespacerswithnewones.

SWINGARMBEARING

Insertthespacerintobearingandchecktheplaywhenmovingthespacerupanddown.

Ifexcessiveplayisnoted,replacethebearingwithanewone.

•DrawouttheswingarmcushionrodupperbearingsG)andtheswingarmpivotbearings~withthespecialtools.

1.'.&?L!09921-20220:Bearingremoverset

IACAUTIONI

Theremovedbearingsmustbereplacedwithnewones.

CUSHIONLEVERBEARING

Insertthespacerintobearingandchecktheplaywhenmovingthespacerupanddown.

Ifexcessiveplayisnoted,replacethebearingwithanewone.

•Drawoutthecushionleverbearingswiththespecialtools.

!Mt!09921-20220:Bearingremoverset

IACAUTIONI

Theremovedbearingsmustbereplacedwithnewones.

CUSHIONLEVERANDCUSHIONLEVERRODS

_{Inspectthecushionleverandcushionleverrodsfordamage.}

_.,,--~--9

_Cl

SWINGARMPIVOTSHAFT

Usingadialgauge,checkthepivotshaftrunoutandreplaceitiftherunoutexceedsthelimit.

1R%L109900-20606:Dialgauge(1/100mm,10mm)

09900-20701:Magneticstand

09900-21304:V-block(100mm)

- Swingarmpivotshaftrunout:Servicelimit:0.3mm(0.01in)

CHAINBUFFER

Inspectthechainbufferforwearanddamage.

Ifanydefectsarefound,replacethechainbufferwithanewone.

REASSEMBLY

Reassembletheswingarminthereverseorderofdisassemblyandremoval.Payattentiontothefollowingpoints:

_LeftQc:::)Right

(!)50N·m

(5.0kgf·m,

36.0lb-ft)

_@

_{_LJ_tilt=:'.'.===~n!t~+--i(!)78N·m}

(7.8kgf·m,56.5lb-ft)

_.....

(!)100N·m

_10.0kgf·m)

⁽_72.5lb-ft

_~

^(!)90N·m

9.0kgf·m)⁽⁶⁵0lb-ft

SWINGARMBEARING

•Pressthebearingintotheswingarmpivotbyusingthespecialtool.

1-looti09941-34513:Steeringraceinstaller

•Presstheswingarmcushionroduppersidebearingwiththespecialtool.

!Mb09941-34513:Steeringraceinstaller

NOTE:

Whenreinstallingthebearing,stampedmarkonbearingmustfaceoutside.

CUSHIONLEVERBEARING

•Pressthebearingsintothecushionleverwiththespecialtool.

nfill09941-34513:Steeringraceinstaller

NOTE:

Wheninstallingthebearing,stampedmarkonbearingmustfaceoutside.

•Applygreasetothebearingsandspacers.

,099000-25010:SUZUKISUPERGREASE"A"

•Assemblethecushionrodontotheswingarmtemporarily.

•Installthetorquelinktemporarily.

•InstallthechaincaseG),mudguard2)andchainbuffer~.

•Applygreasetothebearingsandspacers.

,099000-25010:SUZUKISUPERGREASE"A"

REMOUNTING

Remounttheswingarminthereverseorderofdisassemblyandremoval,andpayattentiontothefollowingpoints.

SWINGARMPIVOTTHRUSTCLEARANCEADJUSTMENTAdjustswingarmpivotthrustclearanceasfollowingprocedure.

•Inserttheswingarmpivotshaftandtightenittothespecifiedtorque.

(!)Swingarmpivotshaft:15N·m(1.5kgf·m,11.0lb-ft)

•HoldtheswingarmpivotshaftG)witha27mmsocketwrenchandtightentheswingarmpivotnut~witha36mmsocketwrenchtothespecifiedtorque.

(!)Swingarmpivotnut:100N·m(10.0kgf·m,72.5lb-ft)

•Tightentheswingarmpivotlocknuttothespecifiedtorquewiththespecialtool.

!@!09940-14940:Swingarmpivotthrustadjusterlocknutwrench

(!)Swingarmpivotlocknut:90N·m(9.0kgf·m,65.0lb-ft)

.....CHASSIS6·53

SHOCKABSORBERANDCUSHIONLEVERMOUNTINGNUT

^{•Installthewashers®andcushionlever.}

•Installtheside-stand.

C!JCushionlevermountingnut:78N·m(7.8kgf·m,56.5lb-ft)Side-standmountingbolt:50N·m(5.0kgf·m,36.2lb-ft)

•Assemblethecushionlever,cushionrodandrearshockab•

sorber.

C!JRearshockabsorbermountingnut(j):50N·m

(5.0kgf·m,36.0lb-ft)Cushionrodnut~:78N·m(7.8kgf·m,56.5lb-ft)

Cushionrodmountingnut@:78N·m(7.8kgf·m,56.5lb-ft)

•Routethebrakehoseandinstallthebrakehoseguides.(c:::::T8-21)

•Remounttherearwheel.(c:::::T6-37)

TORQUELINK

•Tightenthereartorquelinknutstothespecifiedtorque.

C!JTorquelinknut(Front):28N·m(2.8kgf·m,20.0lb-ft)(Rear):34N·m(3.4kgf·m,24.6lb-ft)

•Tightenthebrakehoseunionbolttothespecifiedtorque.(Brakefluidreplacement:c:::::r6-55)

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

FINALINSPECTIONANDADJUSTMENT

Afterinstallingtherearsuspensionandwheel,thefollowingad•

_{justmentsarerequiredbeforedriving.}

*Drivechain:c:::::r2-20

_{•Tirepressure:c:::::r2-26}

^{•Chassisboltsandnuts:c:::::r2-28}

FRONTBRAKE

CONSTRUCTION

_{IFrontbrakelever}

·2Dus!boot

,3'Pistonset

~Pistonseal

($'Dustseal

_{§:Brakecaliperpiston}

^z,Brakepad

~·Brakepadspring

~:Padmountingpin

_{10•Brakehose}

IiBrakehose

~Frontmastercylindermountingbolt

·~Brakehoseunionboll

_{'Q'Calipermountingbolt}

ThCaliperairbleedervalve

·~Caliperhousingbolt

_®)-

^1I

₁₁

_·-----·

ITEM @	N·m 10	kgf·m 1.0	lb-ft 7.0
@	23	2.3	16.5
©	25	2.5	18.1
©	8	0.8	6.0
®	21	2.1	15.1
AWARNING

•Thisbrakesystemisfilledwithanethyleneglycol-basedDOT4brakefluid.Donotusemixdifferenttypesoffluidsuchassilicone-basedorpetroleum-based.

*Donotuseanybrakefluidtakenfromold,usedorunsealedcontainers.Neverreusebrakefluidleftoverfromthelastservicingorstoredforlongperiods.

*Whenstoringthebrakefluid,sealthecontainercompletelyandkeepawayfromchildren.

*Whenreplenishingbrakefluid,takecarenottogetdustintofluid.

*Whenwashingbrakecomponents,usefreshbrakefluid.Neverusecleaningsolvent.

*Acontaminatedbrakediscorbrakepadreducesbrakingperformance.Discardcontaminatedpadsandcleanthediscwithhighqualitybrakecleanerorneutraldetergent.

IACAUTIONI

^{Handlebrakefluidwithcare:thefluidreactschemicallywithpaint,plastics,rubbermaterialsetc.}_-

BRAKEPADREPLACEMENT

•RemovethespringG).

•Removethebrakepadsbyremovingtheclip2)andpadmount·

ingpin®·

ACAUTIONI

•Donotoperatethebrakeleverwhiledismountingthepads.

*Replacethebrakepadsasaset,otherwisebraking

performancewillbeadverselyaffected.

•Installthenewbrakepads.

(!)Padmountingpin:16N·m{1.6kgf·m,11.6lb-ft)

NOTE:

Afterreplacingthebrakepads,pumpthebrakeleverfewtimestocheckforproperbrakeoperationandthencheckthebrakefluidlevel.

BRAKEFLUIDREPLACEMENT

•Placethemotorcycleonalevelsurfaceandkeepthehandle·

barsstraight.

•Removethebrakefluidreservoircapanddiaphragm.

•Suckuptheoldbrakefluidasmuchaspossible.

•Fillthereservoirwithnewbrakefluid.

•Connectaclearhosetothecaliperairbleedervalveandinserttheotherendofhoseintoareceptacle.

•Loosentheairbleedervalveandpumpthebrakeleveruntilold

brakefluidflowsoutofthebleedersystem.

•Closethecaliperairbleedervalveanddisconnectaclearhose.

Fillthereservoirwithnewfluidtotheuppermarkofthereser•

voir.

~SpecificationandClassification:DOT4

IACAUTIONI

Bleedairfromthebrakesystem.(c:::::?'"2-24)

CALIPERREMOVALANDDISASSEMBLY

•RemovethebrakehosefromthecaliperbyremovingtheunionboltG)andcatchthebrakefluidinasuitablereceptacle.

NOTE:

Placearagunderneaththeunionboltonthebrakecalipertocatchanyspiltbrakefluid.

•Removethebrakecaliperbyremovingthecalipermountingbolts(?).

NOTE:

Slightlyloosenthecaliperhousingboltsbeforeremovingthecali•

permountingboltstofacilitatelaterdisassembly.

IACAUTIONI

Neverreusethebrakefluidleftoverfrompreviousser•

vicingandstoredforlongperiodsoftime.

AWARNING

Brakefluid,ifitleaks,willinterferewithsaferunninganddiscolorpaintedsurfaces.Checkthebrakehoseandhosejointsforcracksandfluidleakage.

•Removethebrakepads.(c::::?6-55)

•Separatethecaliperhalvestoremovethecaliperhousingbolts.

•Removethe0-rings.

ACAUTIONI

Replacethe0-ringswithnewones.

•Placearagoverthepistonstopreventitfrompoppingoutandthenforceoutthepistonsusingcompressedair.

ACAUTIONI

Donotusehighpressureairtopreventpistondamage.

•Removethedustsealsandpistonseals.

IACAUTIONI

Donotreusethedustsealsandpistonsealstopreventfluidleakage.

CALIPERINSPECTION

BRAKECALIPER

Inspectthebrakecalipercylinderwallfornicks,scratchesorotherdamage.

BRAKECALIPERPISTON

Inspectthebrakecaliperpistonsurfaceforanyscratchesorotherdamage.

CALIPERREASSEMBLYANDREMOUNTINGReassemblethecaliperinthereverseorderofremovalanddis•assembly.Payattentiontothefollowingpoints:

•Washthecaliperboresandpistonswithspecifiedbrakefluid.

Particularlywashthedustsealgroovesandpistonsealgrooves.

~SpecificationandClassification:DOT4

IACAUTIONI

*Washthecalipercomponentswithfreshbrakefluidbeforereassembly.Neverusecleaningsolventorgaso•linetowashthem.

*Donotwipethebrakefluidoffafterwashingthecom•

ponents.

*Whenwashingthecomponents,usethespecified

brakefluid.Neverusedifferenttypesoffluidorclean•