Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Exterior parts removal and installation

Side frame cover

Removal

Note

the left and right side frame covers are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side.

  1. Remove the bolt (1).
  2.  Remove the side frame cover (2).

Suzuki GSX-R. Side frame cover


  1. Velcro fastening
  2. Bushing

Installation

Installation is in the reverse order of removal.

Front seat

Removal

  1. Remove the side frame covers.
  2.  Remove the front seat by removing the bolts.

Suzuki GSX-R. Side frame cover


Installation

  1. Slide the seat hooks into the seat hook retainers on the frame and tighten the bolts.

Suzuki GSX-R. Side frame cover


  1. Install the side frame covers.

Rear seat / seat tail cover

Removal

Remove the rear seat or seat tail cover with the ignition key.

Rear seat

Suzuki GSX-R. Rear seat


Seat tail cover

Suzuki GSX-R. Seat tail cover


Installation

Slide the hook into the hook retainer and push down firmly until the rear seat/seat tail cover snaps into the locked position.

Suzuki GSX-R. Seat tail cover


Windscreen

Removal

  1. Loosen the rear view mirror mounting nuts.

Suzuki GSX-R. Windscreen


  1. Remove the windscreen (1) by removing the screws.

Suzuki GSX-R. Windscreen


Installation

Install the windscreen in the reverse order of removal.

Pay attention to the following point:

Suzuki GSX-R. Windscreen


Suzuki GSX-R. Windscreen


Note

the screws “a” are 3 mm shorter than the others

Suzuki GSX-R. Windscreen


Tightening torque rear view mirror mounting nut (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Windscreen


Body cowling cover

Removal

  1. Remove the fasteners (8 pcs.).
  2.  Remove the body cowling cover (1).

Suzuki GSX-R. Body cowling cover


Installation

Install the body cowling cover in the reverse order of removal.

Side cowling

Removal

  1. Remove the fasteners and cowling bracket (1).

Suzuki GSX-R. Side cowling


Suzuki GSX-R. Side cowling


  1. Remove the bolts.
  2.  Remove the side cowling (2). (Lh/rh)

Suzuki GSX-R. Side cowling


Suzuki GSX-R. Side cowling


  1. Bushing

Installation

Install side cowling in the reverse order of removal.

Pay attention to the following points:

Suzuki GSX-R. Side cowling


Inner under cowling

Removal

Note

the left and right inner under cowlings are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side.

  1. Remove the side cowling.
  2.  Remove the inner under cowling (1).

Suzuki GSX-R. Inner under cowling


Installation

Install the inner under cowling in the reverse order of removal.

Body cowling

Removal

  1. Remove the body cowling cover.
  2.  Remove the left and right side cowlings.
  3.  Remove the inner under cowlings.
  4.  Remove the rear view mirror.
  5.  Remove the windscreen.
  6. Remove the combination meter. Refer to “combination meter removal and installation” in section 9c .
  7.  Disconnect the turn signal lead wire couplers (1).

Suzuki GSX-R. Body cowling


  1. Disconnect the steering damper lead wire coupler (2).

Suzuki GSX-R. Body cowling


  1. Disconnect the lead wire couplers (3).
  2.  Remove the air intake pipe bolts.

Suzuki GSX-R. Body cowling


  1. Remove the screws.

Suzuki GSX-R. Body cowling


  1. Remove the body cowling assembly (4) forward.

Suzuki GSX-R. Body cowling


  1. Disassemble the body cowling assembly. Refer to “headlight removal and installation” in section 9b .

Installation

Install the body cowling in the reverse order of removal.

Pay attention to the following point:

Intake pipe

Removal

  1. Remove the body cowling.
  2. Remove the intake pipes (1). (Lh & rh)

Suzuki GSX-R. Intake pipe


Installation

Install the intake pipes in the reverse order of removal.

Cowling brace

Removal

  1. Remove the body cowling.
  2.  Remove the cowling brace (1).

Suzuki GSX-R. Cowling brace


Installation

Install the cowling brace in the reverse order of removal.

Pay attention to the following point:

Tightening torque cowling brace mounting bolt (a): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)

Suzuki GSX-R. Cowling brace


Frame cover

Removal

  1. Remove the front and rear seats.
  2. Remove the bolts and fasteners.

Suzuki GSX-R. Frame cover


Suzuki GSX-R. Frame cover


  1. Bushing
  1. Disconnect the seat lock cable (1).

Suzuki GSX-R. Frame cover


  1. Disconnect the rear combination light coupler (2).
  2.  Remove the frame cover assembly from the frame.

Suzuki GSX-R. Frame cover


  1. Disassemble the frame cover assembly. Refer to “rear combination light removal and installation” in section 9b .

Installation

Install the frame cover assembly in the reverse order of removal.

Front fender

Removal

Refer to “front fork removal and installation” in section 2b .

Installation

Refer to “front fork removal and installation” in section 2b .

Rear fender

Removal

Refer to “rear fender construction” .

Installation

Refer to “rear fender construction” .

Fastener removal and installation
Type a Removal Depress the head of fastener center piece (1).  Pull out the fastener (2). Installation Let the center piece stick out toward the head so that the pawls “a” clo ...

Specifications
Tightening torque specifications Note the specified tightening torque is described in the following. “Rear view mirror construction” Reference: for the tightening torque of ...

Other materials:

Rear brake pedal construction
Footrest bracket no. 2 Footrest bracket no. 1 Rear brake peda Footrest holder Footrest 35 N·m (3.5 Kgf-m, 25.5 Lbf-ft) 23 N·m (2.3 Kgf-m, 16.5 Lbf-ft) 18 N·m (1.8 Kgf-m, 13.0 Lbf-ft) Apply grease. Apply thread lock to the ...

Front brake caliper parts inspection
Refer to “front brake caliper disassembly and assembly” . Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the surface of brake caliper pistons for a ...

Throttle valve synchronization
Check and adjust the throttle valve synchronization among four cylinders.  Start the engine and run it in idling condition for warming up.  Stop the warmed-up engine.  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page ...

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