Suzuki GSX-R 1000 Service Manual: Handlebar removal and installation
Removal
- Remove the following parts from the left handlebar.
- left handlebar switch box (1)
- handlebar balancer (2)
- grip rubber (3)
- clutch cable (4)

- Remove the following parts from the right handlebar.
- right handlebar switch box (5)
- handlebar balancer (6)
- throttle grip (7)
- front brake master cylinder (8)
Caution
do not turn the front brake master cylinder
upside down. |

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

- Remove the steering stem head nut (11) and washer
(12).
- 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. |

- Remove the handlebars (14) upward.

- 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.
Note
face the chamfer side of the washer
downward. |

- 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 )
Throttle grip
Grip rubber
Right handlebar switch box
Left handlebar switch box
Right handlebar
Left handlebar
Handlebar expander
Handlebar balancer
...
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:
Generator removal and installation
Removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the generator coupler (1).
Remove the generator cover (2).
...
Radiator inspection and cleaning
Radiator hose inspection
Refer to “cooling system inspection” in section 0b .
Radiator inspection
Inspect the radiator for water leaks. If any defects are
found, replace the radiator with a new one.
If the fins are bent or dented, repair them by carefully
straightening them with the blade of ...
Evaporative emission control system
diagram (only for e-33)
Fuel tank
Fuel-vapor separator
Fuel pump
Fuel feed hose
Fuel shut-off valve
Iap sensor
Surge hose
Evap canister
Purge hose
Evap system purge control solenoid valve
Fue
Hc vapor
Fresh air
Vacuum
...