Suzuki Burgman 400 - Service manual > Front Fork Disassembly and Assembly

Refer to "Front Fork Removal and Installation".

Disassembly

1) Remove the front fork spring (1).

2) Invert the fork and stroke it several times to drain out fork oil.

3) Hold the fork inverted for a few minutes to drain oil.

4) Remove the cylinder bolt (2) using the special tools.

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

5) Remove the cylinder (3), rebound spring (4) and cylinder ring (5).

6) Remove the dust seal (6) and oil seal stopper ring (7).

7) Pull the outer tube out of the inner tube.

NOTE Be careful not to damage the inner tube.

8) Remove the following parts.

• Oil seal (8)
• Oil seal retainer (9)
• Guide metal (10)
• Slide metal (11)
• Oil lock piece (12)

9) Remove the spring (13) from the oil lock piece (14).

Assembly

Assemble the front fork in the reverse order of disassembly. Pay attention to the following points:

! CAUTION

• Thoroughly wash all the component parts being assembled.

  Insufficient washing can result in oil leakage or premature wear of the parts.

• When reassembling the front fork, use new fork oil.
• Use the specified fork oil for the front fork.
• When reassembling, replace the slide metal, guide metal, oil seal, dust seal and cylinder bolt gasket with the new ones.
• Use care not to cause damage to the slide metal surfaces since the surfaces are teflon coated.

Oil lock piece

• Install the spring (1) into the oil lock piece (2) securely.

Inner tube

• Apply fork oil to the guide metal and oil seal lip.

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

Install the following parts onto the inner tube.

• Oil seal (1)
• Oil seal retainer (2)
• Guide metal (3)

! CAUTION When installing the oil seal to inner tube, be careful not to damage the oil seal lip.

• Hold the inner tube vertically, clean the metal groove and install the slide metal by hand.

! CAUTION Do not damage the Teflon coated surface of the inner tube's slide metal when mounting it.

• Apply fork oil to the slide metal.

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

• Install the oil lock piece into the inner tube.

• 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.

• Install the oil seal (1) into the outer tube using the special tool.

Special tool (A): 09940-52861 (Front fork oil seal installer)

• Install the oil seal stopper ring (4) and the dust seal (5).

• Dust seal (5)
• Oil seal stopper ring (4)
• Oil seal (1)
• Oil seal retainer (2)
• Guide metal (3)

See also: