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CHASSIS 8-9 |
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FRONT WHEEL |
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CONSTRUCTION |
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1 |
Brake disc |
6 Front axle |
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2 |
Collar |
7 Front wheel |
ITEM |
N·m |
kgf-m lb-ft |
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3 |
Dust seal |
A Front axle bolt |
A |
100 |
10.0 |
72.5 |
4 |
Bearing |
B Brake disc bolt |
B |
23 |
2.3 |
16.5 |
5 |
Spacer |
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8-10 CHASSIS
REMOVAL AND DISASSEMBLY
• Remove the brake calipers.
Do not operate the brake lever while removing the calipers.
•Loosen two axle pinch bolts 1 on the right front fork leg.
•Remove the front axle bolt 2.
•Remove the under cowling. ( 8-5)
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• Raise the front wheel off the ground and support the motorcy- |
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cle with a jack or a wooden block. |
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Do not carry out the work with the motorcycle resting |
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on the side-stand. Do not support the motorcycle with |
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the exhaust pipe. Make sure that the motorcycle is |
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supported securely. |
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• Loosen two axle pinch bolts 3 on the left front fork leg.
• Draw out the front axle and remove the front wheel.
NOTE:
After removing the front wheel, fit the calipers temporarily to the original positions.
• Remove the collar 4.
CHASSIS 8-11
• Remove the brake discs, left and right.
• Remove the dust seals on both sides with the special tool.
09913-50121: Oil seal remover
The removed dust seals must be replaced with new ones.
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• Remove the wheel bearings with the special tool. |
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09921-20240: Bearing remover set |
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The removed bearings should be replaced with new |
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ones. |
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• Remove the spacer 5.
8-12 CHASSIS
INSPECTION
TIRE INSPECTION ( 8-85)
BRAKE DISC INSPECTION ( 8-70)
AXLE SHAFT
•Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.
09900-20607: Dial gauge (1/100)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Axle shaft runout:
Service Limit: 0.25 mm (0.010 in)
WHEEL
•Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.
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Wheel runout: |
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Service Limit (Axial and Radial): 2.0 mm (0.08 in) |
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•Inspect the play of the wheel bearings by fingerMwhile they are in the wheel. Rotate the inner raceAby finger to inspect for abnormal noise and smooth rotation.
•Replace the bearing in theSfollowing procedure if there is anything unusual.WHEEL BEARINGS
CHASSIS 8-13
REASSEMBLY AND INSTALLATION
Reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:
Left |
Right |
23 N·m
(2.3 kgf-m, 16.5 lb-ft)
23 N·m
(2.3 kgf-m, 16.5 lb-ft)
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100 N·m |
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(10.0 kgf-m, 72.5 lb-ft) |
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WHEEL BEARING
• Apply SUZUKI SUPER GREASE “A” to the wheel bearings.
99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
8-14 CHASSIS
• Install the wheel bearings with the special tools as follows.
09924-84510: Bearing installer set
First install the right wheel bearing, then install the spacer and left wheel bearing.
The sealed cover of the bearing must face outside.
Left |
Right |
Left |
Right |
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Clearance |
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A |
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Spacer |
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• Install the dust seal with the special tool. |
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09913-70210: Bearing installer set
• Apply SUZUKI SUPER GREASE “A” to the dust seal lip.
99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
BRAKE DISC
•Make sure that the brake disc is clean and free of any greasy matter.
•Apply THREAD LOCK to the disc mounting bolts and tighten them to the specified torque.
Brake disc bolt (Front): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
99000-32130: THREAD LOCK SUPER “1360”
CHASSIS 8-15
• Install the collar 1 in the right side.
WHEEL
•Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily.
The directional arrow on the tire should point to the wheel rotation, when remounting the wheel.
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BRAKE CALIPER |
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• Tighten the brake caliper mounting bolts to the specified |
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torque. |
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Front brake caliper mounting bolt: |
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39 N·m (3.9 kgf-m, 28.0 lb-ft) |
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FRONT AXLE
•Hold the front axle with the special tool and tighten the front axle bolt 1 to the specified torque.
09900-18740: Heaxagon socket (24 mm)
Front axle bolt: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
•Tighten two axle pinch bolts 2 on the right fork leg to the specified torque.
Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Move the front fork up and down 4 or 5 times.
8-16 CHASSIS
•Tighten two axle pinch bolts on the left front fork leg to the specified torque.
Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
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