Suzuki Burgman 400 - Service manual > Cylinder / Rebound spring / Cylinder ring

• Install the rebound spring and the cylinder ring to the cylinder and install them together to the inner tube.

NOTE The cylinder ring should be installed onto the cylinder with its oil passage notches "A" facing downward.

Apply thread lock to the cylinder bolt and tighten it to the specified torque using the special tools.

! CAUTION Use a new cylinder bolt gasket to prevent oil leakage.

NOTE Check the front fork for smoothness by stroking it after installing the cylinder.

: Thread lock cement 99000-32050 (Thread Lock Cement 1342 or equivalent)

Special tool
(A): 09940-34520 (T handle)
(B): 09940-34531 (Attachment A)

Tightening torque
Cylinder bolt: 30 N*m (3.0 kgf-m, 21.5 lb-ft)

Front fork oil

• Place the front fork vertically without spring.
• Compress the front fork fully.
• Pour the specified front fork oil into the front fork.

: Fork Oil 99000-99044-10G (FORK OIL or equivalent)

Front fork oil capacity (each leg)
301 ml (10.17/10.60 US/Imp oz)

• Move the inner tube up and down slowly 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.

Hold the front fork vertically and adjust the fork oil level using the special tool.

NOTE When adjusting the fork oil level, remove the fork spring and compress the inner tube fully.

Special tool (A): 09943-74111 (Fork oil level gauge)

Fork oil level "a"
87 mm (3.43 in)

Front fork spring

• Install the fork spring into the front fork.

Front Fork Inspection

Refer to "Front Fork Inspection".

Front Fork Parts Inspection

Refer to "Front Fork Disassembly and Assembly".

Inspect the following parts.

Inner / Outer Tubes

Inspect the inner tube sliding surface and outer tube sliding surface for scuffing. 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 limit, replace it with a new one.

Front fork spring free length "a"
347.6 mm (13.39 in)

Cylinder / Cylinder Ring

Inspect the cylinder (1) and cylinder ring (2) for wear or damage. If any defects are found, replace the cylinder or cylinder ring with a new one.

Specifications

Service Data

Suspension

Unit: mm (in)

Tightening Torque Specifications

NOTE The specified tightening torque is also described in the following.

Reference: For the tightening torque of fastener not specified in this section, refer to "Tightening Torque Specifications".

Special Tools and Equipment

Recommended Service Material

NOTE Required service material is also described in the following.

Special Tool

09940-30230 Socket hexagon (17 mm)

09940-34531 Attachment A

09943-74111 Fork oil level gauge

09940-34520 T handle

09940-52861 Front fork oil seal installer

See also: