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Suzuki DR-Z400S Front Fork Inspection - Spring Free Length & Seal Removal

Service procedure page covering front fork reassembly, removal, and inspection steps with accompanying figures.

AI caption · Photo 16 of 154

This is one page of a motorcycle service manual covering front fork disassembly and inspection procedures. The top section instructs the mechanic to remove the oil seal (1), oil seal retainer (2), outer tube antifriction metal (3), inner tube antifriction metal (4), and oil lock piece (5), accompanied by an exploded illustration of these components on the fork tube. A CAUTION box states that the outer and inner tube's antifriction metals must be replaced along with the oil seal and dust seal whenever the front fork is assembled. The INSPECTION section covers three checks: (1) Fork Spring — measure the free length and replace the spring if it is shorter than the service limit of 561 mm (22.1 in); (2) Inner and Outer Tube — inspect the sliding surfaces for scuffing or damage and replace both tubes if damage is found; (3) Damper Rod Ring — inspect for wear or damage and replace the fork cylinder ring if damaged. Illustrations show the fork spring measurement, the inner and outer tubes, and the damper rod ring location. The page was uploaded to a 2005 Suzuki DR-Z400S gallery, though the page itself does not state model or year applicability.

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Frequently asked questions

What is the service limit for the front fork spring free length?
561 mm (22.1 in). If the fork spring free length is shorter than this service limit, replace the fork spring with a new one.
What parts must be replaced when assembling the front fork?
Per the CAUTION, the outer and inner tube's antifriction metals must be replaced along with the oil seal and dust seal when assembling the front fork.
What should I do if the inner or outer fork tube sliding surface is scuffed or damaged?
Replace the inner tube and outer tube with new ones if any damage is found on the sliding surfaces.
What parts are removed in the fork seal removal step?
The oil seal, oil seal retainer, outer tube antifriction metal, inner tube antifriction metal, and oil lock piece.
What do I do if the damper rod ring is worn or damaged?
Replace the fork cylinder ring with a new one.

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