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 )
Handlebar components
Throttle grip
Grip rubber
Right handlebar switch box
Left handlebar switch box
Right handlebar
Left handlebar
Handlebar expander
Handlebar balancer
...
Handlebars inspection
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:
Rear brake pedal construction
Footrest bracket no. 2
Footrest bracket no. 1
Rear brake peda
Footrest holder
Footrest
35 N·m (3.5 Kgf-m,
25.5 Lbf-ft)
23 N·m
(2.3 Kgf-m, 16.5 Lbf-ft)
18 N·m
(1.8 Kgf-m, 13.0 Lbf-ft)
Apply grease.
Apply thread lock to the ...
Battery
Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the fi system instantly when reverse
power is applied.
Removing any battery terminal of a running engine is
strictly prohibited. The moment such removal is made,
...
Rear brake master cylinder components
Reservoir cap
Plate
Diaphragm
Reservoir tank
Reservoir hose
Brake hose
Brake hose union bolt
Brake hose connector
Master cylinder
Spring
Piston/cup set
Push rod
Dust boot
23 N·m (2.3 Kgf-m,
16.5 Lbf-ft)
10 N·m
...