Oil seal and dust seal
- Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube.
1. Dust seal; 2. Oil seal stopper ring; 3. Oil seal; 4. Oil seal retainer
Caution:
- When installing the oil seal to outer tube, be careful not to damage the oil seal lip.
- Do not use solvents for washing to prevent oil seal damage.
- Apply fork oil to the Anti-friction metals and lip of the oil seal.
- Make sure that the oil seal stopper ring has been fitted securely.
- Insert the inner tube into the outer tube and fit the oil seal and dust seal with the special tool.
- 09940-52861: Front fork oil seal installer
Note: Stamped mark on the oil seal should face outside.
Damper rod bolt
- Insert the inner rod/damper rod (cartridge) into the inner tube.
- Apply THREAD LOCK SUPER to the damper rod bolt.
- 99000-32110: THREAD LOCK SUPER "1322" or equivalent
Caution: Use a new damper rod bolt gasket 1 to prevent oil leakage.
- Tighten the damper rod bolt to the specified torque with the special tool.
- 09940-30221: Front fork assembling tool
- Damper rod bolt: 40 Nm (4.0 kgf·m, 29.0 lb·ft)
Fork oil
- Place the front fork vertically without spring.
- Compress it fully.
- Pour specified front fork oil up to the top level of the outer tube.
- 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent
- Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
- 09940-52841: Inner rod holder
Note: Refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air.
- Refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil.
- Keep the front fork vertically and wait 5 - 6 minutes.
Note:
- Always keep oil level over the cartridge top end, or air may enter the cartridge during this procedure.
- Take extreme care so as to pump out air completely.
- Hold the front fork vertically and adjust fork oil level with the special tool.
Note: When adjusting the fork oil level, compress the outer tube fully without the fork spring.
- Fork oil level: 133 mm (5.2 in)
- 09943-74111: Front fork oil level gauge
Front fork inner rod lock nut
- Loosen the lock nut 1 to the bottom of inner rod threads.
Fork spring
- Install the fork spring as shown in the illustration.
- Install the spring 1 and spacer 2.
Front fork cap bolt
- Pull up the inner rod with the special tool А.
- Compress the spring with the special tool В and then insert the special tool С between the lock nut and the spacer.
- 09940-52841: Inner rod holder А
- 09940-94930: Front fork spacer holder А
- 09940-94922: Stopper plate С (11 mm)
- Slowly turn the cap bolt 1 until the inner rod is lightly seated.
- Hold the cap bolt 1 and tighten the lock nut 2 to the specified torque.
- Inner rod lock nut: 15 Nm (1.5 kgf·m, 11.0 lb·ft)
- Remove the special tools.
- Fit the O-ring to the front fork cap bolt and apply fork oil.
Caution: Use a new O-ring to prevent oil leakage.