Toyota RAV4 manuals

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:

Spark plug inspection and cleaning
Inspect spark plug every 6 000 km (4 000 miles, 12 months) Heat range Remove the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .  Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appe ...

Iap sensor removal and installation
Removal Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Disconnect the coupler (1) and vacuum hose (2).  Remove the iap sensor (3) from the air cleaner box. Installation Install the iap sensor in the reverse ord ...

Cylinder head disassembly and assembly
Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Intake, exhaust, no. 1 Or no. 2) So that they can be installed in their original locations ...

© 2011-2019 Copyright www.suzukigsxr.org