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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 n·m (2.3 Kgfm, 16.5 Lbf-ft) handlebar clamp bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Handlebar removal and installation


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

Suzuki GSX-R. Handlebar removal and installation


: Grease 99000–25010 (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:

Precautions
Precautions for suspension Refer to “general precautions” in section 00 (page 00-1). All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension ...

Oil cooler / oil cooler hose removal and installation
Refer to “electrical components location” in section 0a . Removal Turn the ignition switch off.  Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Drain engine oil. Refer to “engine oil and filter replacement” in section 0b . ...

Engine stop switch inspection
Inspect the engine stop switch in the following procedures:  turn the ignition switch off.  Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Disconnect the right handlebar switch coupler (1). Inspect the engine stop ...

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