Suzuki GSX-R 1000 Service Manual: Exterior parts removal and installation

Side frame cover

Removal

1. Remove the bolt (1).
2.  Remove the side frame cover (2).

Installation

Installation is in the reverse order of removal.

Front seat

Removal

1. Remove the side frame covers.
2.  Remove the front seat by removing the bolts.

Installation

1. Slide the seat hooks into the seat hook retainers on the frame and tighten the bolts.

2. Install the side frame covers.

Rear seat / seat tail cover

Removal

Remove the rear seat or seat tail cover with the ignition key.

Rear seat

Seat tail cover

Installation

Slide the hook into the hook retainer and push down firmly until the rear seat/seat tail cover snaps into the locked position.

Windscreen

Removal

1. Loosen the rear view mirror mounting nuts.

2. Remove the windscreen (1) by removing the screws.

Installation

Install the windscreen in the reverse order of removal.

Pay attention to the following point:

•  insert two nuts into the hole of cowling brace.

• Insert four nuts (top and bottom ones) into the windscreen.

• Tighten the screws.

• Tighten the rear view mirror mounting nuts to the specified torque.

Tightening torque rear view mirror mounting nut (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Body cowling cover

Removal

1. Remove the fasteners (8 pcs.).
2.  Remove the body cowling cover (1).

Installation

Install the body cowling cover in the reverse order of removal.

Side cowling

Removal

1. Remove the fasteners and cowling bracket (1).

2. Remove the bolts.
3.  Remove the side cowling (2). (Lh/rh)

Installation

Install side cowling in the reverse order of removal.

Pay attention to the following points:

•  when installing the right side cowling, make sure that the fuel tank drain hose and breather hose are routed properly. Refer to “fuel tank drain hose and breather hose routing diagram” in section 1g .
•  When installing the bracket, set the punch mark “a” to the front and upper side.

Inner under cowling

Removal

1. Remove the side cowling.
2.  Remove the inner under cowling (1).

Installation

Install the inner under cowling in the reverse order of removal.

Body cowling

Removal

1. Remove the body cowling cover.
2.  Remove the left and right side cowlings.
3.  Remove the inner under cowlings.
4.  Remove the rear view mirror.
5.  Remove the windscreen.
6. Remove the combination meter. Refer to “combination meter removal and installation” in section 9c .
7.  Disconnect the turn signal lead wire couplers (1).

8. Disconnect the steering damper lead wire coupler (2).

9. Disconnect the lead wire couplers (3).
10.  Remove the air intake pipe bolts.

11. Remove the screws.

12. Remove the body cowling assembly (4) forward.

13. Disassemble the body cowling assembly. Refer to “headlight removal and installation” in section 9b .

Installation

Install the body cowling in the reverse order of removal.

Pay attention to the following point:

• adjust the headlight beam if necessary. Refer to “headlight beam adjustment” in section 9b .

Intake pipe

Removal

1. Remove the body cowling.
2. Remove the intake pipes (1). (Lh & rh)

Installation

Install the intake pipes in the reverse order of removal.

Cowling brace

Removal

1. Remove the body cowling.
2.  Remove the cowling brace (1).

Installation

Install the cowling brace in the reverse order of removal.

Pay attention to the following point:

•  tighten the cowling brace mounting bolts (1) to the specified torque.

Tightening torque cowling brace mounting bolt (a): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)

Frame cover

Removal

1. Remove the front and rear seats.
2. Remove the bolts and fasteners.

3. Disconnect the seat lock cable (1).

4. Disconnect the rear combination light coupler (2).
5.  Remove the frame cover assembly from the frame.

6. Disassemble the frame cover assembly. Refer to “rear combination light removal and installation” in section 9b .

Installation

Install the frame cover assembly in the reverse order of removal.

Front fender

Removal

Refer to “front fork removal and installation” in section 2b .

Installation

Refer to “front fork removal and installation” in section 2b .

Rear fender

Removal

Refer to “rear fender construction” .

Installation

Refer to “rear fender construction” .