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Suzuki GSX-R 1000 Service Manual: Handlebar removal and installation

Removal

  1. Remove the following parts from the left handlebar.
  1.  left handlebar switch box (1)
  2.  handlebar balancer (2)
  3.  grip rubber (3)
  4.  clutch cable (4)

Suzuki GSX-R. Handlebar removal and installation


  1. Remove the following parts from the right handlebar.
  1.  right handlebar switch box (5)
  2.  handlebar balancer (6)
  3.  throttle grip (7)
  4.  front brake master cylinder (8)
Caution

do not turn the front brake master cylinder upside down.

Suzuki GSX-R. Handlebar removal and installation


  1. Loosen the handlebar clamp bolts (9) and front fork upper clamp bolts (10).

Suzuki GSX-R. Handlebar removal and installation


  1. Remove the steering stem head nut (11) and washer (12).
  2.  Remove the steering stem upper bracket assembly (13).
Note

place a rag under the steering stem upper bracket to prevent scratching the body cowling and the combination meter.

Suzuki GSX-R. Handlebar removal and installation


  1. Remove the handlebars (14) upward.

Suzuki GSX-R. Handlebar removal and installation


  1. Remove the clutch lever assembly (15) from the left handlebar.

Suzuki GSX-R. Handlebar removal and installation


Installation

Install the handlebars in the reverse order of removal.

Pay attention to the following points:

Suzuki GSX-R. Handlebar removal and installation


Note

face the chamfer side of the washer downward.

Suzuki GSX-R. Handlebar removal and installation


Suzuki GSX-R. Handlebar removal and installation


Tightening torque front fork upper clamp bolt (a): 23 nm (2.3 Kgfm, 16.5 Lbf-ft) handlebar clamp bolt (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Handlebar removal and installation


Tightening torque steering stem head nut (c): 90 nm (9.0 Kgf-m, 65.0 Lbf-ft)

Suzuki GSX-R. Handlebar removal and installation


: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Handlebar removal and installation


: Handle grip bond (handle
grip bond (commercially available))

Suzuki GSX-R. Handlebar removal and installation


Suzuki GSX-R. Handlebar removal and installation


Handlebar components
Throttle grip Grip rubber Right handlebar switch box Left handlebar switch box Right handlebar Left handlebar Handlebar expander Handlebar balancer ...

Handlebars inspection
Refer to handlebar removal and installation (page 6b- 2). Inspect the handlebars for distortion and damage. If any defect is found, replace the handlebar with a new one. ...

Other materials:

Engine coolant
Coolant level The engine coolant solution should be between "f" (full) and "1..:' (Low) level lines on the engine coolant reservoir. If the level is lower than "1..:' (Low) level line, bring it up to "f" (full) level by adding 50:50 mixture of distilled water ...

Voltage check
If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.  With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.  If measurements were taken as shown ...

Front fork components
Front fork cap O-ring Rebound damping force adjuster rod Compression damping force adjuster rod Piston rod nut O-ring Piston ring Rod guide case Spring Piston rod Spring collar b Spring Spring collar a Slide bushing Outer tu ...

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