Front wheel

Th1360: Apply THREAD LOCK SUPER " 1360".

G: Apply SUPER GR EASE " A".

Tightening torque

@: 18 - 28 N·m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

@: 50 - 80 N·m

(5.0 - 8.0 kg-m, 36.0 - 58.0 lb-ft)

• Support the motorcycle with the center stand and jack.

• Remove the brake caliper by removing the mounting bolts.

09900-00410: Hexagon wrench set

NOTE:

Do not operate the brake lever while removing the front wheel.

CAUTION:

• Loosen the ax le pinch bolt.

• Remove the axle shaft and front wheel.

•

09900-00410: Hexagon wrench set

INSPECTION AND DISASSEMBLY

Inspect the lip of dust seal for damage.

TIRE

Refer to page 7-33.

WHEEL BEARINGS

Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bear­ ing if there is anything unusual.

Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.

09900-20606: Dial gauge (1/100) 09900-20701: Magnetic stand

09900-21304: V-block set (100 mm) Service limit: 0.25 mm (0.010 in)

Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosen wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Service limit (Axial and Radial): 2.0 mm (0.08 in)

•

09941-50110: Bearing remover

•

• After inserting the wedge bar from the opposite side, lock the wedge bar in the slit of the adaptor.

• Drive out the wheel bearing by knocking the wedge bar.

CAUTION:

The removed bearings should be replaced with new ones.

Reassemble and remount the front wheel in the reverse ord­ er of removal and disassembly. Pay attention to the follow­ ing points:

WHEEL BEARING

• Apply grease to the bearing before installing.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE II A"

99000-25010: SUZUKI SUPER GREASE " A"

• Install the wheel bearings as follows by using the special tool.

09924-84510: Bearing installer set

NOTE:

First install the left wheel bearing, then install the right wheel bearing. The sealed cover on the bearing is positioned out side. Re fer to the illustration on next page.

.. •

R ight bea ri ng (New part)

Lef t side

R ight side

Lef t I iht 11

side r-

Clea rance

• Make su re t hat the bra ke d isc is clea n a nd free of a ny greasy matter. A ppl y TH R E A D LOCK SU P E R " 1360" to the d isc mou nti ng bolts a nd tighten them to t he specif ied torq ue.

Tightening torque: 18 - 28 N-m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

99000-32130: THREAD LOCK SUPER " 1360"

• Before i nsta ll i ng the speedometer gea rbox, appl y grease to i ts d ust sea l l i p.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE " A"

(For the other models)

99000-25010: SUZUKI SUPER GREASE " A"

• F it the d rive l ugs CD i nto t he recesses 0 of t he whee l h u b.

•

• When tightening the front axle, make sure that the speed­ ometer gearbox is in position and the speedometer cable does not bend sharply.

• Tighten the axle shaft to the specified torque.

Tightening torque: 50 - 80 N·m

(5.0 - 8.0 kg-m, 36.0 - 58.0 lb-ft)

• Tighten the axle pinch bolt to the specified torque.

Tightening torque: 18 - 28 N·m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

• Tighten the brake caliper mounting bolts to the specified torque.

Tightening torque: 30 - 48 N·m

(3.0 - 4.8 kg-m, 21.5 - 35.0 lb-ft)

NOTE:

Push the pistons all the way into the caliper and remount the caliper.

FRONT BRAKE