Front Fork Disassembling and Assembling

KAYABA Pneumatic Spring Front Fork PSF2

RM-Z250L6

PresentatörPresentationsanteckningarLatest version of KAYABA pneumatic spring fork

RM-Z250L6 Front Fork Disassembling

Warning Oil may jet out from the air bulb and may stick to your eyes and mouth. When releasing the air pressure, place a lag over the air bulb and use a screwdriver to press the air bulb.

1. Release air Release the air pressure by pressing the air valve with a screwdriver.

PresentatörPresentationsanteckningarHold the fork in vertical position so that no oil stays around the valve area.

2. Remove the top cap using the special tool.

09955-04910 Front fork cap wrench (49 mm) (Newly developed for RM-Z250L6)

RM-Z250L6 Front Fork Disassembling

PresentatörPresentationsanteckningar15 mm spanner to be used for the lock nut of piston rod.

3. Drain fork oil. Move the inner tube several strokes to drain the fork oil.

RM-Z250L6 Front Fork Disassembling

4. Remove the fork damper assembly. (1) While clamping the axle holder with a vise, loosen the center bolt at the bottom of the fork to remove the fork damper assembly.

09900-18720 Hexagon bit socket (14 mm)

09955-04920 Front fork cylinder holder (Newly developed for RM-Z250L6)

RM-Z250L6 Front Fork Disassembling

PresentatörPresentationsanteckningarSpecial tool “Front fork cylinder holder” is newly developed for this model.

(2) Remove the snap ring and the center bolt at the fork bottom.

RM-Z250L6 Front Fork Disassembling

PresentatörPresentationsanteckningarSpecial tool “Front fork cylinder holder” is newly developed for this model.

5. Drain fork oil from the fork damper assembly. Stroke the piston rod several times while plugging the piston rod hole with your finger.

RM-Z250L6 Front Fork Disassembling

Warning Oil may jet out from the air bulb and may stick to your eyes and mouth. When releasing the air pressure, place a lag over the air bulb and use a screwdriver to press the air bulb.

PresentatörPresentationsanteckningarPlug the piston rod top hole. Otherwise oil will spread out form the hole when pushing down the piston rod.

6. Separate the inner tube out of the outer tube. (1) Remove the dust seal, scraper and stopper ring. (2) To separate the inner tube from the outer tube while rotating inner tube, pull out the inner tube several times until the guide bush come out from the outer tube.

RM-Z250L6 Front Fork Disassembling

Stopper ring Scraper Dust seal

PresentatörPresentationsanteckningarTo prevent the bushes from damage, gently pull out the inner tube to tapping out the guide bush on outer tube by slide bush on inner tube.Scraper is a new item as fork inner parts.

(3) Inspect all the parts for wear or damage, If they are worn or damaged, replace with them with new ones.

RM-Z250L6 Front Fork Assembling

Slide bush

Scraper Dust seal

Guide bush

Seal retainer

Collar Oil seal

Stopper ring

Scraper is a plastic part provided on the dust seal to scrape dust entered over the dust seal.

RM-Z250L6 Front Fork Assembling

(1)

(2)

Guide bush

Seal retainer

Collar

Oil seal

Scraper

Dust seal

Stopper ring

PresentatörPresentationsanteckningarScraper prevents oil contaminated with dust to come up to the oil seal lip.

Fitting direction of the scraper

RM-Z250L6 Front Fork Assembling

Outer tube Oil seal

Dust seal

1. Install dust seal, scrapper, stopper ring, etc. on the inner tube. (1) Apply fork oil to the lip of new oil seal and new dust seal. (2) Cover the inner tube with a plastic film. (3) Install the following parts to the inner tube. - Dust seal - Scrapper - Stopper ring - Oil seal (4) Remove the plastic film and install the following parts. - Collar - Seal retainer - Guide bush Slide bush

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarUse plastic film to prevent seal lips from damage when inserting the parts to inner tube.

2. Insert the guide bush (1) and seal retainer (2). Insert the guide bush and seal retainer with the special tool.

(1)

(2)

(1)

(2) 09940-52861 Front fork oil seal installer set

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarVisually check the guide bush is completely seated.

3. Insert the collar (1), oil seal (2) and stopper ring (3). Insert the collar and oil seal with the special tool, and then attach the stopper ring securely to the stopper ring groove.

(1)

(2)

(1)

(3)

RM-Z250L6 Front Fork Assembling

09940-52861 Front fork oil seal installer set

PresentatörPresentationsanteckningarVisually check the groove of stopper ring appears. (not be covered by oil seal)

4. Insert the scrapper (1) and dust seal (2).

Direction of the scrapper Longer rib is faced to outer tube side.

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningar

5. Install the fork damper assembly. (1) Clean the center bolt threads and install the new gasket and O-ring. (2) Install the center bolt and the fork damper assembly and tighten to the specified torque with the special tools. (3) Install the snap ring.

Center bolt: 70 N.m (7.0 kgf-m, 50.5 lbf-ft)

09900-18720 Hexagon bit socket (14 mm) 09955-04920 Front fork cylinder holder

RM-Z250L6 Front Fork Assembling

Gasket Snap ring

O-ring

6. Pour fork oil. Pour fork oil up to the top level of the inner tube while holding the front fork vertically in fully compressed condition.

KYB SUSPENSION OIL KHL 15-11

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarThe specified oil is different one from the oil used on the other Suzuki models.The oil will be set as Suzuki genuine fork oil in future. Parts no. and release time are not fixed at this stage.

7. Attach the fork cap to the piston rod temporarily. (1) Screw in the lock nut of the piston rod completely by hand. (2) Screw in the fork cap completely by hand. Note: There is a gap between the top cap and lock nut in this condition. (3) Turn up the lock nut until it contacts with the top cap. (4) While holding the lock nut, tighten the top cap temporarily.

Gap 1st step: Turn up

2nd step: Turn down

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarThis procedure is to seat the piston rod on the fork cap securely. Piston rod hole is connected to the damping adjuster hole on the fork cap. Due to this, fork cap needs to be tightly seated on the piston rod.

8. Fork oil feeding to damper assembly. (1) Raise the outer tube while holding the fork cap. (2) Tighten the fork cap temporarily. (3) Move the outer tube several strokes.

RM-Z250L6 Front Fork Assembling

(4) Remove the fork cap. (5) Slide down the outer tube slowly to fully to the bottom position. (6) Raise the fork cap and pour fork oil up to the top level of inner tube. (7) While plugging the top cap hole with a finger, move the piston rod several times.

RM-Z250L6 Front Fork Assembling

Plug the hole

PresentatörPresentationsanteckningarPlug the hole of the fork cap. Otherwise oil will spread out from the hole when pushing down the piston rod.

8. Breed air between inner tube and outer tube. (1) Pour fork oil up to the top level of outer tube. (2) While holding the fork cap in raised position, slowly move the outer tube several strokes to bleed air. (3) Check no air bubble comes from the gap between the inner tube and outer tube.

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarThere is narrow space allowing air staying there. Pour oil over the inner tube upper end and bleed air in this operation

9. Adjust fork oil level. (1) Remove the fork cap, and slowly move down the piston rod.

CAUTION Air may suck from the top hole of the piston rod if moving up and down the piston rod. Do not move up and down the piston rod.

RM-Z250L6 Front Fork Assembling

(3) Adjust the fork oil level with a special tool in fully compressed condition.

Front fork oil level Standard setting: 115 mm (4.5 in)

RM-Z250L6 Front Fork Assembling

PresentatörPresentationsanteckningarOuter tube and piston rod needs to be fully down

10. Install the fork cap. (1) Slowly raise the piston rod. (2) Screw in the lock nut of the piston rod completely by hand. (3) Screw in the fork cap completely by hand. Note: There is a gap between the top cap and lock nut in this condition. (4) Turn up the lock nut until it contacts with the top cap.

Gap 1st step: Turn up

2nd step: Turn down

RM-Z250L6 Front Fork Assembling

(4) While holding the lock nut, tighten the top cap to the specified torque. (5) Clamp the lower mounting part of the outer tube with a vise, and tighten the fork cap to the specified torque.

Fork cap: 45 N.m (4.5 kgf-m, 32.5 lbf-ft)

Lock nut/fork cap: 29 N.m (2.9 kgf-m, 21.0 lbf-ft)

RM-Z250L6 Front Fork Assembling

L = 300 mm TS = 45 N・m LS = 50 mm

300 mm ×45 N・m

300 mm + 50 mm 350

13500 38.57 N・m = = = T

Calculation of tightening torque To tighten to the specified torque with the combination of the special tool and a torque wrench, application torque on the torque wrench scale needs to be calculated in the following formula.

In the case of the fork cap tightening with a torque wrench which effective length is 300 mm

RM-Z250L6 Front Fork Assembling

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