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:
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Transmission components” “gearshift lever construction”
“gearshift shaft / gearshift cam plate components” “gearshift
shaft construction”
Special to ...
Starter motor inspection
Refer to “starter motor disassembly and assembly” .
Carbon brush
Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If either carbon brush is defective, replace the brush
holder set with a new one.
Measure the length “a” of the carbon brushes using a
v ...
Oil jet removal and installation
Piston cooling oil jet
Removal
Remove the engine assembly. Refer to “engine assembly removal” in
section 1d .
Remove the crankshaft assembly. Refer to “engine
bottom side disassembly” in section 1d (page 1d-
49).
Remove the piston cooling oil jets (1) from the upper
cra ...