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:
Drive chain
This motorcycle has a master link
type drive chain. We recommend
that you take your motorcycle to
an authorized suzuki dealer if the
drive chain needs replacing.
The condition and adjustment of
the drive chain should be checked
each day before you ride. Always
follow the guidelines for ins ...
Gearshift lever
This motorcycle has a 6-speed
transmission which operates as
shown. To shift properly, squeeze
the clutch lever and close the
throttle at the same time you
operate the gearshift lever. Lift the
gearshift lever to upshift and
depress the lever to downshift.
Neutral is located between lo ...
Steering / steering damper related parts
inspection
Refer to “steering / steering damper removal and installation” .
Inspect the removed parts for the following
abnormalities:
Steering stem
Distortion of the steering stem and brackets.
Bearing
Bearing wear or damage
abnormal bearing noise
race wear or damage
&nbs ...