Suzuki 2005 DR-Z400SMK5 Supplementary Service Manual page 20

SLIDE BUSHING AND GUIDE BUSHING
Inspect the "teflon coating metals" (slide bushing and guide
bushing) for wear or damage. If they are worn or damaged,
replace them with new ones.
Inspect the metal particles on the "teflon coating metals". If they
are not clean, clean them with a nylon brush and fork oil.
REASSEMBLY
NOTE:
* Clean all fork parts before reassembling.
* Replace the O-rings, oil seal and dust seal with the new ones.
* Apply specified front fork oil when installing the O-rings, slide
bushing, guide bushing, damper unit and other sliding parts.
INNER TUBE
• Apply front 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 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.
DR-Z400SMK5 ('05-MODEL) 19