Suzuki GSX-R 1000 Service Manual: Exterior parts construction

Suzuki GSX-R 1000 Service Manual / Body and accessories / Exterior parts / Repair instructions / Exterior parts construction

Suzuki GSX-R. Exterior parts construction

Upper cowling bracket : set the punch mark to the front and upper side.
Rear view mirror cushion : set the dent side to inside.
To frame
To headlight assembly
To sprocket cove
To side-stand bracket

Rear fender construction

Electric parts holder bracket Rear fender (front) Rear fender (rear) Rear fender (lower) Rear fender guard (e-24 only) ...

Other materials:

Engine top side assembly
Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Cylinder head Install the dowel pins and a new cylinder head gasket (1) to the cylinder. Caution use a new gasket to prevent gas leakage. Place the cylinder head ...

Cam chain tensioner inspection
Inspect the cam chain tensioner in the following procedures: remove the cam chain tensioner. Refer to “cam chain guide / cam chain tensioner removal and installation” . Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new ...

Muffler / muffler chamber / exhaust pipe removal and installation
Removal Loosen the muffler connecting bolts (1). Remove the mufflers (2) by removing the mounting bolt and nut (3). Note support the muffler to prevent it from falling. Remove the side cowlings. Refer to “exterior parts removal and installation” in secti ...