Front suspension and handlebars of motorcycle Suzuki DL1000 V-Strom (2002-2012)

Front fork — construction
1. О-ring; 2. Washer; 3. Spacer; 4. Spring; 5. Inner rod/damper rod (cartridge); 6. Inner tube; 7. Slide metal; 8. Gasket; 9. Dust seal; 10. Oil seal stopper ring; 11. Oil seal; 12. Oil seal retainer; 13. Guide metal; 14. Oil lock piece; 15. Outer...

Front fork — removal and disassembly*
Remove the front wheel. (6-9) Remove the front fender bolt (1) and brake hose bolt (2). Loosen the front fork upper clamp bolts (3). Note: Slightly loosen the front fork cap bolts (4) before loosening the lower clamp bolts to facilitate later...

Front fork — inspection
Inner and outer tubes Inspect the inner tube outer surface and the outer tube inner surface for scratches. If any defects are found, replace them with the new ones. Fork spring Measure the fork spring free length. If it is shorter than the service...

Front fork — reassembly and remounting*
Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attension to the following points: Tube metals and seals Hold the inner tube vertically and clean the metal groove and install the guide metal by hand as...

Steering and handlebar — construction
1. Handlebars; 2. Steering stem upper bracket; 3. Dust seal; 4. Bearing upper; 5. Bearing lower; 6. Steering stem lower bracket; 7. Dust cover; 8. Steering stem nut; 9. Handlebar balancer; 10. Expander; 11. Spacer; 12. Washer; 13. Expander; A....

Steering and handlebar — removal*
Handlebars Remove the handlebar balancer (1). Remove the brake/clutch lever covers (2). Note: Do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer...

Steering and handlebar — inspection and disassembly
Inspect the removed parts for the following abnormalities. Handlebars distriction Race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of the steering stem If any abnormal points are found, replace defective parts with...

Steering and handlebar — reassembly and remounting*
Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points: Outer races Press in the upper and lower outer races using the special tool. 09941-34513: Steering outer race installer...

Steering and handlebar — steering tension adjustment
Check the steering movement in the following procedure. By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20-30 mm (0.8-1.2 in). Check to make sure that the cables and wire harnesses are properly routed....