Reassembly - Suzuki RM-Z250 Service Manual

18-12 FRONT FORK AND STEERING

REASSEMBLY


* Clean all fork parts before reassembling.
* Replace the O-rings, oil seal and dust seal with new
ones.
* Apply specified front fork oil when installing the
O-rings, slide bushing, guide bushing, damper unit
and sliding parts.
INNER TUBE
• Apply fork oil to the oil seal lip and the dust seal.
• Cover the inner tube with a plastic film.
• Install the following parts to the inner tube:
New dust seal 1
Stopper ring 2
New oil seal 3

* Scratches on the oil seal lip can cause oil leaks.
* When installing the seals, place a plastic film over
the bushing attachment groove and edges of the
inner tube to avoid damaging the seals' lip.
NOTE:
The side of the oil seal that has a mark should face the dust
seal.
• Remove the plastic film and then install the seal retainer 4,
guide bushing 5 and slide bushing 6.
• Clean the parts and keep them free from dust.
NOTE:
Inspect the bushings for burrs. If there is a burr, remove it with a
knife, taking care not to peel off the teflon coating. If the bush-
ings have a large crack or excessive play after installing them,
replace them with new ones.
• Insert the inner tube into the outer tube.
• Install a new oil seal 3 with the special tool until the stopper
ring groove of the outer tube can be seen.
 09940-52861: Front fork oil seal installer set
• Attach the stopper ring securely to the stopper ring groove of
the outer tube.