Suzuki k10 forks disassembly & assembly

I love my k10 forks.  I found that there was very little documentation of them online so when I did come across this useful information, I was sure to keep it handy.  This fork assembly is for k15's, but the same concept to take apart your k10's... except that there is no inner spring, instead the less beefy outer springs.  I found the k15 images on Moped Army, but I figured it would be better to transcribe the directions to make it easier.  At the end of the entry I included all of the original photos, but throughout the instructions, I included the Figures.  Hope this helps anyone interested in getting their Suzuki fork on!   You can click on any of the images to make them larger.  Oh, one final note, the manual calls for 125cc of SAE 10W/30 or ATF.  That comes to 4.22 fl oz, but I personally prefer just slightly more than that for more of a firmer ride and less squish.  I go about 4.4 fl oz  Anyway, here ya go:


Disassembly
   Two basic types of tube forks are used.  Figure 13 illustrates the first type and Figure 14 illustrates the second type. 

   The first type is distinguished from the first type by the presence of the outer tube nut (5, Figure 13) which must be removed to disassemble the forks.  The second type does not have the outer tube nut but has a cylinder retaining bold in the bottom of each fork leg.
   To disassemble the first time with the outer tube nut, perform Step 1. To disassemble the second time, proceed to Step 2.

1.  To disassemble the first time of fork, perform the following steps:
   a. Remove fork tube head bolt. (Figure 15).

   b. Remove spring guide (Figure 16).

   c. Remove fork spring (Figure 17).

   d. Invert the fork tube, and drain the oil (Figure 18). Discard the drained oil.

   e. Remove the dust seal (Figure 19)

   f. Hold outer tube bracket, then remove outer tube nut (Figure 20). If the special tool is not available, wrap a piece of rubber sheeting or section of the inner tube around the outer tube nut, then clamp the nut in a vise (Figure 21). Be careful not to deform the tube by clamping the vise too tightly.

   g. Turn the outer tube counterclockwise to separate the tubes.  The outer tube may be turned easily by using the front axle shaft as a lever.
   h. Slip out inner tube.

2. To disassemble the second type of fork, perform the following steps:
   a. Remove the cylinder retaining bolt.  See Figure 22.

      NOTE: These model forks are equipped with either a small spring steel snap wire retainer on the top of the outer tube or a large snap ring.   The forks which use the large snap ring can be disassembled by just removing the snap ring. It is not necessary to remove the cylinder retaining bolt.
   b. Draw out outer tube (Figure 23).

    c. Loosen upper and lower clamp bolts and remove fork tube (Figure 24).

     d. Loosen fork cap bolt and remove inner tube cap bolt.  Remove spring (Figure 25).

3.  Assembly is the reverse of the disassembly procedure.  Keep the following points in mind:
   a. Replace all O-rings and tube seals.
   b. Clean inside of outer tubes with solvent before assembly.
   c. Refill front forks (Chapter Two)

Inspection
1.  Aseemble inner and outer tubes (Figure 26) then slide them together.  Check for looseness, noise, or binding.  Replace defective parts.

2.  Any scratches or roughness on the inner tube in the area where it passes through the oil seal will damage the oil seal. Examine this area carefully.
3.  Inspect the dust seal carefully.  If this seal is damaged, foreign material will enter the fork.
4.  Check fork spring for weark.  If you replace one spring, replace the other one also.
5. Replace complete outer tube nut if the oil seal is worn or damaged.

Best,
Andrew Buck Michael