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Suzuki GSX-R 1000 Service Manual: Cushion lever removal and installation

Suzuki GSX-R 1000 Service Manual / Suspension / Rear suspension / Repair instructions / Cushion lever removal and installation

Removal

  1. Remove the right side cowling and side frame covers. Refer to “exterior parts removal and installation” in section 9d .
  2.  Support the motorcycle with a jack to relieve load on the cushion levers.
  3.  Remove the left muffler and muffler chamber heat guard no. 2. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .
  4.  Remove the rear shock absorber. Refer to “rear shock absorber removal and installation” .
  5.  Remove the cushion levers (1).

Suzuki GSX-R. Cushion lever removal and installation


Installation

Install the cushion levers in the reverse order of removal.

Pay attention to the following point:

Tightening torque cushion lever mounting nut (a): 98 n·m (9.8 Kgfm, 71.0 Lbf-ft) cushion rod rear mounting nut (b): 98 n·m (9.8 Kgf-m, 71.0 Lbf-ft)

Suzuki GSX-R. Cushion lever removal and installation


Rear shock absorber disposal
Refer to “rear shock absorber removal and installation” . The rear shock absorber unit contains high-pressure nitrogen gas. Mishandling can cause explosion.  Keep away from f ...

Cushion lever inspection
Refer to “cushion lever removal and installation” . Cushion lever Inspect the cushion levers for damage. If any defects are found, replace the cushion levers with new ones. ...

Other materials:

Gearshift shaft oil seal / bearing removal and installation
Removal Remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation” .  Remove the gearshift shaft oil seal (1). Remove the bearings (2) and (3) with the special tools. Special tool (a): 09921–20210 (bearing remover (12 mm)) ...

Starter motor removal and installation
Removal Turn the ignition switch off and disconnect the battery (–) lead wire (1).  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Disconnect the starter motor lead wire (2).  Remove the starter motor (3). ...

Conrod crank pin bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. Place the plastigauge axially along ...

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