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 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:

Chassis bolt and nut inspection
Tighten chassis bolt and nut initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque. Steering stem lock-nut 80 nm (8.0 Kgf-m, 58.0 Lbf-ft) Stee ...

Rear seat
The seat lock is located under the left frame cover. To remove the rear seat, insert the ignition key into the lock and turn it clockwise. Raise the front end of the seat and slide it forward. To reinstall the seat, slide the seat hooks into the seat hook retainers and push down firm ...

DTC c28 (p1655): secondary throttle valve actuator (stva) malfunction
Detected condition and possible cause Detected condition Possible cause The operation voltage does not reach the stva. Ecm does not receive communication signal from the stva. Stva can not operate properly or its motor locked Stva malfunction.   ...

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