reality vs shop manual - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
Suspension and Tire Tech For all discussions related to your suspension and tire set-ups.

LinkBack Thread Tools Display Modes
post #1 of 1 Old 02-25-2019, 08:44 AM Thread Starter
Join Date: Jan 2013
Location: western PA
Posts: 359
reality vs shop manual

I disassembled my front forks on my 2008 DL1000. As I prepare to reassemble them, I was checking the shop manual for torque specifications. Lo and behold, what my shop manual shows as the fork assembly is not what is actually on my bike.

The shop manual discusses a fork tube which has a solid fork cap. My bike has a 'spring adjustor' which threads through the fork cap. See the differences in the two photos attached. In each case the fork cap is item #19 -- in one it is solid, in the other a spring adjustor threads through it. In reality, my bike has item #21 as a 'spring adjustor' which threads through the fork cap. The damper rod then threads into the spring adjustor item #21 rather than into the fork cap itself, which the shop manual wants you to believe. At least my shop manual wants me to believe you thread the damper rod into the fork cap, not a spring adjustor.

Seemingly this is not a huge issue. BUT, the manual says to bottom the fork cap onto the nut which is on the damper rod. That nut is item #14 in either picture. Since I can not obviously bottom the fork cap (#19) to the nut (#14), I assume that I should instead bottom the spring adjustor (#21) to the nut (#14).

My questions are, based on a more accurate shop manual which you may have:

1. What is the torque for the nut when I bottom it to the adjustor? My shop manual indicates I should use 14.5 ft-lbs if I bottomed it to the solid fork cap (#19). But since I am bottoming it to the adjustor itself (#21) should I be using a different torque setting?

2. My shop manual suggests the nut (#14) be set 10.5mm from the top of the damper rod prior to bottoming the fork cap to it. This is the measurement the manual recommends as it instructs me to bottom the solid fork cap (#19) to the nut (#14). But since the spring adjustor on my bike can and does extend well below the base of the fork cap for preload adjustments, what should that measurement be from the top of the damper rod to where I set the nut (#14)?? If your shop manual, unlike mine, walks you through a reassembly of the forks with a spring adjustor that extends through the fork cap, what does the shop manual indicate the measurement is from the top of the damper rod to the nut?


Attached Images
File Type: jpg forks with solid fork cap.jpg (583.1 KB, 8 views)
File Type: jpg forks with spring adjustor in fork cap.jpg (670.6 KB, 7 views)
Yarz1 is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
Service Manual availability Stoopy DL1000A - 2014-2016 31 04-22-2015 11:34 PM
2014 Online Shop Manual ToadRide DL1000A - 2014-2016 6 12-15-2014 03:09 PM
2012 Vee Factory Shop Manual BakRdsBnd2Da DL1000 from 2002-2012 5 09-07-2014 06:35 AM
Reality vs Suzuki service manual Majster81 DL650A - 2012-2016 15 02-24-2014 04:36 PM
Buy a new service manual ? solo1 DL1000 from 2002-2012 7 11-08-2010 08:32 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome