GS500K4/FK4 (’04-MODEL) 23
• Hold the front fork vertically and adjust the fork oil level with
the special tool.
'
Front fork oil level: 110 mm (4.3 in)
&
09943-74111: Front fork oil level gauge
• Apply fork oil lightly to a new O-ring and install it to the front
fork cap bolt.
(
99000-99044-10G:
SUZUKI FORK OIL #10 or equivalent fork oil
• Temporarily tighten the cap bolt.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points.
• When installing the front fork assembly, align the upper sur-
face
A
of the inner tube with the surface
B
of the steering
upper bracket.
• Tighten the front fork upper clamp bolt
1
to the specified
torque.
#
Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the front fork lower clamp bolt
2
to the specified
torque.
#
Front fork lower clamp bolt: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
• Tighten the front fork cap bolt to the specified torque.
#
Front fork cap bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Recheck that the surface
A
is flush with the surface
B
.
• Install the front fender and front wheel.
NOTE:
Before tightening the front fender brace mounting screws, move
the front forks up and down several times.
Summary of Contents for 2004 GS500
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Page 36: ...Prepared by January 2004 Part No 99501 34150 03E Printed in Japan 36 ...
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