Suzuki GSX-R 1000 Service Manual: Cushion lever removal and installation

Removal

1. Remove the right side cowling and side frame covers. Refer to “exterior parts removal and installation” in section 9d .
2.  Support the motorcycle with a jack to relieve load on the cushion levers.
3.  Remove the left muffler and muffler chamber heat guard no. 2. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .
4.  Remove the rear shock absorber. Refer to “rear shock absorber removal and installation” .
5.  Remove the cushion levers (1).

Installation

Install the cushion levers in the reverse order of removal.

Pay attention to the following point:

•  set the cushion levers so that the arrow mark “a” points forward.
•  Install the washers (1) between the cushion rod and cushion levers.
•  Tighten each nut to the specified torque.

Tightening torque cushion lever mounting nut (a): 98 n·m (9.8 Kgfm, 71.0 Lbf-ft) cushion rod rear mounting nut (b): 98 n·m (9.8 Kgf-m, 71.0 Lbf-ft)

• Install the rear shock absorber. Refer to “rear shock absorber removal and installation” .
•  Install the muffler chamber heat guard no. 2 And left muffler. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .
•  Install the side frame covers and right side cowling.

  Refer to “exterior parts removal and installation” in section 9d .