Reassembly - Suzuki DF 90 Service Manual

REASSEMBLY

Assembly is reverse order of disassembly with special atten-
tion to following steps.
• Do not reuse O-rings after removal, always use new
O-rings.
• Lubricate all components and O-rings with PTT fluid
before assembly.
• Do not reuse PTT fluid, always refill with new fluid.
TILT ROD
When tightening the piston retaining nut on the tilt rod piston,
apply Thread lock 1342 to the threads.
Tighten the nut to specified torque.
99000-32050: Thread Lock 1342
Piston retaining nut: 100 N . m (10.0 kg-m, 72.5 lb-ft)
Installing tilt rod / piston
Pour 100 ml of PTT fluid into cylinder.
Insert the free piston into cylinder and push it down to the bot-
tom of the cylinder.
Pour PTT fluid into the cylinder until it is topped off.
Insert the tilt rod/piston into cylinder and thread the tilt cylinder
head by hand until fully seated.
Tighten the cylinder head to specified torque using special tool.
Tilt cylinder head: 160 N . m (16.0 kg-m, 115.5 lb-ft)
09944-09420: PTT cylinder cap tool
DF140 "K2" ('02) MODEL
Free piston
Cylinder
11-31
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