Suzuki Burgman 400 - Service manual > Repair Instructions

Front Fork Components

1. Front fork top cap
2. O-ring
3. Washer
4. Front fork spring
5. Cylinder ring
6. Cylinder
7. Rebound spring
8. Inner tube
9. Inner tube slide metal
10. Dust seal
11. Oil seal stopper ring
12. Oil seal
13. Oil seal retainer
14. Guide metal
15. Oil lock piece
16. Outer tube
17. Gasket
18. Cylinder bolt
19. Front axle pinch bolt

a : 45 N*m (4.5 kgf-m, 32.5 lb-ft)

b : 30 N*m (3.0 kgf-m, 21.5 lb-ft)

: Apply thread lock to thread part.

: Apply fork oil.

: Do not reuse.

Front Fork Removal and Installation

Removal

1) Remove the front leg shield. Refer to "Front Leg Shield Removal and Installation".

2) Remove the front wheel assembly. Refer to "Front Wheel Assembly Removal and Installation".

! CAUTION

• Make sure that the motorcycle is supported securely.
• Do not operate the front brake lever with the front wheel removed.

3) Disconnect the brake hose clamp (1) from the front fender.

4) Remove the brake hose clamp bolt (2).

5) Remove the front fender by removing the bolts (3) (L & R).

6) Remove the front fork cap bolt (4) and washer using the special tool.

! CAUTION Use caution when removing the front fork cap bolt since the spring force is applied to the cap bolt.

Special tool (A): 09940-30230 (Socket hexagon (17 mm) )

7) Loose the front fork clamp bolts (5) and remove the front fork (6).

NOTE Hold the front fork by the hand to prevent sliding out of the steering stem.

Installation

1) Insert the front fork inner tube top end into the steering stem all the way until the step of mounting hole has been contacted and tighten the clamp bolts temporarily.

2) Replace the O-ring of the front fork cap bolt and apply fork oil.

! CAUTION Use a new O-ring to prevent oil leakage.

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

3) Install the washer and temporarily tighten the front fork cap bolt and tighten the front fork clamp bolts (1) to the specified torque.

Tightening torque
Front fork clamp bolt (a): 23 N*m (2.3 kgf-m, 16.5 lb-ft)

4) Tighten the front fork cap bolt (2) to the specified torque using the special tool.

Special tool (A): 09940-30230 (Socket hexagon (17 mm) )

Tightening torque
Front fork cap bolt (b): 45 N*m (4.5 kgf-m, 32.5 lb-ft)

5) Install the front fender.

6) Tighten the brake hose clamp bolt.

7) Connect the brake hose clamp to the front fender.

8) Install the front wheel assembly. Refer to "Front Wheel Assembly Removal and Installation".

! WARNING After remounting the brake caliper, pump the brake lever until the pistons push the pads correctly.

NOTE Before tightening the front axle and front axle pinch bolts, move the front fork up and down four or five times.

See also: