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Suzuki GSX-R 1000 Service Manual: Steering / steering damper removal and installation

Suzuki GSX-R 1000 Service Manual / Steering / Steering / handlebar / Repair instructions / Steering / steering damper removal and installation

Removal steering damper

  1. Turn the ignition switch off.
  2.  Disconnect the steering damper solenoid coupler (1).

Suzuki GSX-R. Steering damper


  1. Remove the lower bracket cover (2).

Suzuki GSX-R. Steering damper


  1. Remove the steering damper mounting nut (3) while holding the lock-nut (4).
  2. Remove the steering damper mounting bolt (5).
  3.  Remove the steering damper (6).

Suzuki GSX-R. Steering damper


Steering

  1. Support the motorcycle with a jack or wooden block.
Caution

do not work by using side stand. Do not support the motorcycle with exhaust pipe.

Make sure that the motorcycle is supported securely.

  1. Remove the front wheel assembly. Refer to “front wheel assembly removal and installation” in section 2d .
  2.  Remove the front forks. Refer to “front fork removal and installation” in section 2b .
  3.  Remove the steering damper. Refer to “steering / steering damper removal and installation” .
  4.  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
  5. Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .
  6.  Disconnect the ignition switch lead wire coupler (1) and immobilizer antenna lead wire coupler (for e- 02, 19, 24, 51) (2).

Suzuki GSX-R. Steering damper


  1. Remove the brake hose clamp bolt (3).

Suzuki GSX-R. Steering damper


  1. Remove the steering stem head nut (4) and washer (5).
  2.  Remove the steering stem upper bracket assembly (6).

Suzuki GSX-R. Steering damper


Note

it is not necessary to remove the ignition switch from the upper bracket when servicing the steering system.

  1. Remove the steering stem lock-nut (7), washer and steering stem nut (8) with the special tools
Note

when loosening the stem nuts, hold the steering stem lower bracket to prevent it from falling.

Special tool (a): 09940–14911 (steering stem nut
socket wrench) (b): 09940–14960 (steering stem nut
socket wrench)

Suzuki GSX-R. Steering damper


  1. Remove the steering stem lower bracket.
  2.  Remove the dust seal cover (9), dust seal (10), upper bearing inner race (11) and upper bearing (12).

Suzuki GSX-R. Steering damper


Installation

Install the steering in the reverse order of removal.

Pay attention to the following points:

Bearing

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Installation


Suzuki GSX-R. Installation


Steering stem nut

Special tool (a): 09940–14911 (steering stem nut
socket wrench) (b): 09940–14960 (steering stem nut
socket wrench)

Tightening torque steering stem nut (a): 45 n·m (4.5 Kgf-m, 32.5 Lbfft) then turn back 1/4 – 1/2

Suzuki GSX-R. Steering stem nut


Note

this adjustment will vary from motorcycle to motorcycle.

Suzuki GSX-R. Steering stem nut


Suzuki GSX-R. Steering stem nut


Special tool (a): 09940–14911 (steering stem nut
socket wrench) (b): 09940–14960 (steering stem nut
socket wrench)

Tightening torque steering stem lock-nut (b): 80 n·m (8.0 Kgf-m, 58.0 Lbf-ft)

Suzuki GSX-R. Steering stem nut


Steering stem upper bracket

Install the front forks and steering stem upper bracket in the following points:

Suzuki GSX-R. Steering stem upper bracket


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

Suzuki GSX-R. Steering stem upper bracket


Steering damper

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Steering damper


Tightening torque steering damper bolt (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft) steering damper nut (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Steering damper


Inspection after installation

Steering damper construction
Steering damper Dust seal Bearing 23 N·m (2.3 Kgf-m, 16.5 Lbf-ft) Apply grease. ...

Steering / steering damper related parts inspection
Refer to “steering / steering damper removal and installation” . Inspect the removed parts for the following abnormalities: Steering stem Distortion of the steering stem and brackets. ...

Other materials:

Stp sensor removal and installation
Removal Remove the throttle body. Refer to “throttle body removal and installation” in section 1d (page 1d- 10).  Remove the stp sensor (1) with the special tool. Special tool : 09930–11950 (torx wrench (5 mm)) Note prior to disassembly, mark the stp sensor’s origina ...

DTC “c49” (p1656): pair control solenoid valve circuit malfunction
Detected condition and possible cause Detected condition Possible cause Pair control solenoid valve voltage is not input to ecm Pair control solenoid valve circuit open or short.  Pair control solenoid valve malfunction.  Ecm malfunction. ...

Ckp sensor inspection
Refer to “electrical components location” in section 0a . Ckp sensor peak voltage Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). Disconnect the ckp sensor coupler (1). Note be sure that all of the couplers are connect ...

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