Suzuki GSX-R1000 Lock Set Replacement
If you've lost the keys to your Suzuki GSX-R1000 or simply want to change your locks for enhanced security, follow our step-by-step guide to replacing the lock sets on your motorcycle.
You can purchase the lock sets separately, but it's much more cost effective to get the complete Suzuki lock set that includes all three locks: the ignition/steering lock set; the fuel tank cap lock set; and the seat lock set. Watch the video above and follow the steps below to replace the lock set on a Suzuki GSXR1000.
Tools and Parts- Suzuki GSX-R1000 Lock Set Replacement
- Ratchet and extensions
- 10mm, 36mm sockets
- 4mm, 5mm, 6mm Allens
- T40 security Torx
- Side cutters
- Torque wrench
- Lock set
PRO TIP: Drain the fuel tank or run it dry before replacing your GSX-R ignition/steering lock set, since you'll need to remove the fuel tank to complete the task.
Replace Suzuki GSX-R1000 Ignition/Steering Lock Set
Step 1. Remove the 36mm steering stem head nut.
Step 2. Remove the 6mm pinch bolts clamping the steering stem head to the fork tubes.
Step 3. Lift the motorcycle slightly so there is no tension on the forks.
PRO TIP: When jacking a GSX-R from the underside, put a piece of wood between the jack and the bike to protect the exhaust.
Step 4. Pry open the clamp slots in the steering stem head and lift it off the fork tubes.
Step 5. Remove the bolt from the front of the fuel tank and the fuel tank front cover.
Step 6. Remove the seat and disconnect the battery to eliminate the possibility of sparks. Don't work on the fuel system until the battery is disconnected.
Step 7. Disconnect the fuel line and the electrical connector under the center of fuel tank, and the two vent hoses under the rear of the fuel tank.
Step 8. Remove the 5mm Allen pivot bolt from the rear of the tank and lift the tank off the motorcycle.
Step 9. Remove the airbox cover and the air filter beneath it.
Step 10. Remove the 10mm bolt at the front of the airbox, and disconnect the sensor under the right side of the airbox. Loosen the clamps under the airbox, carefully lift the airbox off the motor, and move it back to access the ignition switch cable.
Step 11. Cover the engine intakes with a clean rag or shop towels to prevent dirt or debris from falling into the throttle bodies.
Step 12. Disconnect the ignition switch cable from the wiring harness, and remove the steering stem head complete with old ignition/steering lock set.
Step 13. Remove the two screws holding the ignition/steering lock set to the steering stem head. The screws require a T40 security Torx bit to remove them.
Step 14. Install the new ignition/steering lock set into the steering stem head.
Step 15. Reinstall the steering stem head back onto the fork tubes and push it down until it is fully seated.
Step 16. Route the ignition switch cable back down to the wiring harness and reconnect it.
PRO TIP: Before you reinstall the fuel tank, now is an ideal opportunity to replace your GSX-R's spark plugs.
Step 17. Spray the intake boots with contact/brake cleaner to make sliding the airbox into the boots easier. Reinstall the airbox onto the motor, then reconnect the sensor and tighten the boot's clamps.
Step 18. Reinstall the air filter (or use this opportunity to install a new air filter) and the airbox cover.
Step 19. Reinstall the 36mm steering stem head nut and torque it to 65 foot-pounds.
Step 20. Reinstall the steering stem head pinch bolts and tighten them.
Replace Suzuki GSX-R1000 Fuel Tank Cap Lock Set
NOTE: If you don't have the keys to the fuel tank cap lock, skip to Step 2.
Step 1. Remove the five Allen bolts from the fuel tank cap lock set, release the lock's latch with the key, and remove the lock set from the tank. Next, skip to Step 6.
Step 2. Remove the five Allen bolts from the fuel pump on the underside of the tank and remove the fuel pump assembly. Then carefully drain out any remaining fuel from the tank.
PRO TIP: Because fuel vapor is extremely volatile and prone to ignition, allow the fuel tank to fully vent and any fuel vapors to dissipate before working on the tank.
Step 3. Remove the five Allen bolts from the fuel tank cap lock set.
Step 4. Using a long Philips screwdriver, remove the two screws on both sides of the fuel tank lock set latch on the inside of the fuel tank, and remove the lock set from the tank.
PRO TIP: Rotate the fuel tank lock set to make accessing each of the two screws easier.
Step 5. Reinstall the fuel pump assembly and tighten the Allen bolts.
Step 6. Install the new the fuel tank lock set and tighten the Allen bolts.
PRO TIP: Before you reinstall the fuel tank, take advantage and replace your GSX-R's spark plugs.
Step 7. Reinstall the 5mm Allen pivot bolt into the rear of the tank.
Step 8. Reconnect the fuel line and the electrical connector under the center of fuel tank, and the two vent hoses under the rear of the fuel tank.
Step 9. Reinstall the fuel tank front cover.
Step 10. Reconnect the battery.
Replace Suzuki GSX-R1000 Seat Lock Set
Step 1. Remove the plastic rivets from the front of the left rear frame cover to access the seat lock set.
Step 2. Slide the cable out from the mounting bracket and the seat lock itself.
Step 3. Slide the retaining clip off the seat lock set, lift the bracket off and remove the seat lock set from the rear frame cover.
Step 4. Install the new seat lock set through the rear frame cover. Reinstall the bracket and retaining clip, and reattach the cable to the seat lock set and the bracket.
Step 5. Reconnect the left rear frame cover with the plastic rivets, then reinstall the seat and you're done.