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)

2. 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)

3. Loosen the handlebar clamp bolts (9) and front fork upper clamp bolts (10).

4. Remove the steering stem head nut (11) and washer (12).
5.  Remove the steering stem upper bracket assembly (13).

6. Remove the handlebars (14) upward.

7. Remove the clutch lever assembly (15) from the left handlebar.

Installation

Install the handlebars in the reverse order of removal.

Pay attention to the following points:

• when installing the clutch lever assembly to the left handlebar, align the slit of lever holder with the punch mark “a”.

• Install the handlebars temporarily to the front forks.
• Install the upper bracket (1), washer (2) and steering stem head nut (3) temporarily.

• Insert the protrusion “b” of the handlebar into the hole “c” of the steering stem upper bracket.

• Tighten the front fork upper clamp bolts (4) and handlebar clamp bolts (5) to the specified torque.

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)

• Tighten the steering stem head nut (6) to the specified torque.

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

• Install the front brake master cylinder. Refer to “front brake master cylinder assembly removal and installation” in section 4a .
• Apply grease to the end of the throttle cables and cable pulley.

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

• Insert the projection “d” of the right handlebar switch box into the hole of the right handlebar.

• Apply a handle grip bond “e” onto the left handlebar before installing the handlebar grip.

: Handle grip bond (handle
grip bond (commercially available))

• Insert the projection “f” of the left handlebar switch box into the hole of the left handlebar.

• After installing the steering, the following adjustments are required before driving.

•  Throttle cable routing (refer to “throttle cable routing diagram” in section 1d )
•  clutch cable routing (refer to “throttle cable routing diagram” in section 1d )
•  throttle cable play (refer to “throttle cable play inspection and adjustment” in section 1d )
•  clutch cable play (refer to “clutch cable play inspection and adjustment” in section 0b )