Suzuki GSX-R 1000 Service Manual: Handlebar removal and installation
Removal
- Remove the following parts from the left handlebar.
- left handlebar switch box (1)
- handlebar balancer (2)
- grip rubber (3)
- clutch cable (4)
- Remove the following parts from the right handlebar.
- right handlebar switch box (5)
- handlebar balancer (6)
- throttle grip (7)
- front brake master cylinder (8)
| Caution do not turn the front brake master cylinder upside down. |
- Loosen the handlebar clamp bolts (9) and front fork upper clamp bolts (10).
- Remove the steering stem head nut (11) and washer (12).
- 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. |
- Remove the handlebars (14) upward.
- Remove the clutch lever assembly (15) from the left handlebar.
Installation
Install the handlebars in the reverse order of removal.
Pay attention to the following points:
- when installing the clutch lever assembly to the left handlebar, align the slit of lever holder with the punch mark “a”.
- Install the handlebars temporarily to the front forks.
- Install the upper bracket (1), washer (2) and steering stem head nut (3) temporarily.
| Note face the chamfer side of the washer downward. |
- Insert the protrusion “b” of the handlebar into the hole “c” of the steering stem upper bracket.
- Tighten the front fork upper clamp bolts (4) and handlebar clamp bolts (5) to the specified torque.
Tightening torque front fork upper clamp bolt (a): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft) handlebar clamp bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- Tighten the steering stem head nut (6) to the specified torque.
Tightening torque steering stem head nut (c): 90 n·m (9.0 Kgf-m, 65.0 Lbf-ft)
- Install the front brake master cylinder. Refer to “front brake master cylinder assembly removal and installation” in section 4a .
- Apply grease to the end of the throttle cables and cable pulley.
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Insert the projection “d” of the right handlebar switch box into the hole of the right handlebar.
- Apply a handle grip bond “e” onto the left handlebar before installing the handlebar grip.
: Handle grip bond (handle
grip bond
(commercially available))
- Insert the projection “f” of the left handlebar switch box into the hole of the left handlebar.
- After installing the steering, the following adjustments are required before driving.
- Throttle cable routing (refer to “throttle cable routing diagram” in section 1d )
- clutch cable routing (refer to “throttle cable routing diagram” in section 1d )
- throttle cable play (refer to “throttle cable play inspection and adjustment” in section 1d )
- clutch cable play (refer to “clutch cable play inspection and adjustment” in section 0b )
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:
Brake pad
Front
Rear
Inspect the front and rear brake
pads to see if they are worn down
to the grooved wear limit line 1. If
a pad is worn to the grooved wear
limit line, it must be replaced with
a new one. After replacing either
the front or rear brake pads, the
brake lever or pedal must be
...
Camshaft sprocket
Inspect the camshaft sprocket in the following
procedures:
remove the intake and exhaust camshafts. Refer to “engine top side
disassembly” .
Inspect the teeth of each camshaft sprocket for wear
or damage.
If they are worn or damaged, replace the sprocket/
camshaft assembl ...
Exhaust control valve inspection
Inspect exhaust control valve
initially at 1 000 km (600 miles, 2 months) and every
12 000 km (7 500 miles, 24 months) thereafter
Inspect exhaust control valve as follows:
remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Check t ...