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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:

Front wheel related parts inspection
Refer to front wheel assembly removal and installation . Tire Refer to tire inspection in section 0b . Front brake disc Refer to front brake disc inspection in section 4b . Dust seal Inspect the lip of dust seals for wear or damage. If any defects are found, replace the dust seal ...

Starter motor will not run
Note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action Yes No 1 Shift the transmission into neutral.  Grasp the clutch lever, turn on the ignition switch ...

The sport of motorcycling
Your motorcycle and this owner's manual have been designed by people like you who enjoy motorcycling. People become motorcyclists for many reasons. For starters, street riding is fun and invigorating. But no matter why you became a motorcyclist, or how experienced you are, you will eventu ...

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