Metals and seals
Hold the inner tube vertically and clean the metal groove and install the guide metal by hand as shown.
![](https://motoinstruction.ru/img/suzuki/14/120581.jpg)
Caution!
- Use special care to prevent damage to the "Teflon" coated surface of the guide metal when mounting it.
- When installing the oil seal to inner tube, be careful not to damage the oil seal lip.
- Replace the removed metals and seals with new ones.
- Apply fork oil to the Anti-friction metals and lip of the oil seal.
Assemble the following parts as shown.
![](https://motoinstruction.ru/img/suzuki/14/120582.jpg)
1. Oil seal; 2. Oil seal retainer; 3. Guide metal; 4. Slide metal
Note: Stamped mark on the oil seal must face upward.
Install the oil lock piece (5) into the inner tube.
![](https://motoinstruction.ru/img/suzuki/14/120583.jpg)
Install the inner tube into the outer tube with care not to drop the oil lock piece out.
Note: After installing the inner tube into the outer tube, keep the oil lock piece into the inner tube by compressing the front fork fully.
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.
![](https://motoinstruction.ru/img/suzuki/14/120584.jpg)
Install the oil seal stopper ring (6) and the dust seal (7).
![](https://motoinstruction.ru/img/suzuki/14/120585.jpg)
![](https://motoinstruction.ru/img/suzuki/14/120586.jpg)
A. Dust seal; B. Oil seal stopper ring; C. Oil seal; D. Oil seal retainer; E. Guide metal
Cylinder
Install the rebound spring (1) to the cylinder (2).
Apply fork oil to the cylinder ring.
Install the cylinder into the front fork.
![](https://motoinstruction.ru/img/suzuki/14/120587.jpg)
Apply THREAD LOCK to the cylinder bolt.
Caution! Use a new gasket (3) to prevent oil leakage.
![](https://motoinstruction.ru/img/suzuki/14/120588.jpg)
- 99000-32050: THREAD LOCK "1342"
Tighten the cylinder bolt to the specified torque with the special tools.
- 09940-34520: "T" Handle
- 09940-34531: Attachment A
- Cylinder bolt: 20 N·m (2.0 kgf·m, 14.5 lb·ft)
Notes:
- If the cylinder turns together with the cylinder bolt, temporarily install the fork spring, spacer, washer and cap bolt to prevent the cylinder from turning.
- Check the front fork for smoothness by stroking it after installing the cylinder.
Fork oil
Place the front fork vertically without spring.
Compress the front fork fully.
Pour the specified front fork oil into the front fork.
- 99000-99001-SS8: SUZUKI FORK OIL SS-08
- Front fork oil capacity (each leg): 524 ml (17.7/18.5 US/Imp oz)
![](https://motoinstruction.ru/img/suzuki/14/120589.jpg)
Move the inner tube up and down several strokes until no more bubbles come out from the oil.
Keep the front fork vertically and leave it during 5-6 minutes.
Note: Take extreme attention to pump out air completely.
![](https://motoinstruction.ru/img/suzuki/14/120590.jpg)
Hold the front fork vertically and adjust the fork oil level with the special tool.
Note: When adjusting the fork oil level, remove the fork spring and compress the inner tube fully.
- 09943-74111: Front fork oil level gauge
- Fork oil level: 143 mm (5.63 in)
- 99000-99001-SS8: SUZUKI FORK OIL SS-08
![](https://motoinstruction.ru/img/suzuki/14/120591.jpg)
Fork spring
Install the fork spring (1) into the front fork.
Install the washer (2) and spacer (3).
![](https://motoinstruction.ru/img/suzuki/14/120592.jpg)
Note: The smaller spring pitch end (A) must face downward.
![](https://motoinstruction.ru/img/suzuki/14/120593.jpg)
Apply fork oil lightly to the O-ring.
Caution! Use a new O-ring to prevent oil leakage.
Install the spring adjuster to the front fork cap bolt.
![](https://motoinstruction.ru/img/suzuki/14/120594.jpg)
Apply fork oil lightly to the O-ring.
Caution! Use a new O-ring to prevent oil leakage.
Tighten the front fork cap bolt temporarily.
![](https://motoinstruction.ru/img/suzuki/14/120595.jpg)
Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts.
![](https://motoinstruction.ru/img/suzuki/14/120596.jpg)
Tighten the front fork cap bolt (4) to the specified torque.
- Front fork cap bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/120597.jpg)
Loosen the front fork lower clamp bolt.
Align the top of the inner tube to the upper surface of the steering stem upper bracket.
Tighten the front fork upper and lower clamp bolts.
- Front fork upper clamp bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
- Front fork lower clamp bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/120598.jpg)
Install the front wheel. (7-10)
Install the front brake calipers. (7-63)
Note: After install the brake calipers, front brake should be efficient by pumping the front brake lever.
![](https://motoinstruction.ru/img/suzuki/14/120599.jpg)