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)
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.24.jpg)
- 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. |
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.25.jpg)
- Loosen the handlebar clamp bolts (9) and front fork
upper clamp bolts (10).
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.26.jpg)
- 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. |
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.27.jpg)
- Remove the handlebars (14) upward.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.28.jpg)
- Remove the clutch lever assembly (15) from the left
handlebar.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.29.jpg)
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”.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.30.jpg)
- 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. |
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.31.jpg)
- Insert the protrusion “b” of the handlebar into the hole
“c” of the steering stem upper bracket.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.32.jpg)
- 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)
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.33.jpg)
- 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)
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.34.jpg)
- 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.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.36.jpg)
- Apply a handle grip bond “e” onto the left handlebar
before installing the handlebar grip.
: Handle grip bond (handle
grip bond
(commercially available))
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.38.gif)
- Insert the projection “f” of the left handlebar switch
box into the hole of the left handlebar.
![Suzuki GSX-R. Handlebar removal and installation](images/books/111/16/index.39.jpg)
- 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:
Cushion rod inspection
Refer to “cushion rod removal and installation” .
Collar and spacer
Remove the collar and spacer from the cushion rod.
Inspect the collar and spacer for any flaws or other
damage. If any defects are found, replace it with a
new one.
Cushion rod bearing
Insert the collar a ...
Clutch removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Disconnect the ckp sensor coupler (1).
Remove the clutch cover (2).
...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Front fork components”
Special tool
...