Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Generator removal and installation

Removal

  1. Drain engine oil. Refer to engine oil and filter replacement in section 0b .
  2.  Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .
  3.  Disconnect the generator coupler (1).

Suzuki GSX-R. Generator removal and installation


  1. Remove the generator cover (2).

Suzuki GSX-R. Generator removal and installation


  1. Remove the gasket (3) and dowel pins.

Suzuki GSX-R. Generator removal and installation


  1. Hold the generator rotor with the special tool and remove the generator rotor bolt.

Special tool (a): 0993044530 (rotor holder)


Suzuki GSX-R. Generator removal and installation


  1. Screw in the special tool to the crankshaft.
  2.  Remove the generator rotor (4) using the special tool.

Special tool (b): 0993030460 (rotor remover
bolt) (c): 0993034970 (rotor remover)


Suzuki GSX-R. Generator removal and installation


Suzuki GSX-R. Generator removal and installation


  1. Remove the generator stator (5).

Suzuki GSX-R. Generator removal and installation


Installation

Install the generator in the reverse order of removal. Pay attention to the following points:

Tightening torque generator stator set bolt (a): 11 nm (1.1 Kgf-m, 8.0 Lbf-ft) generator lead wire set bolt (b): 5.5 Nm (0.55 Kgfm, 4.0 Lbf-ft)

: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

Suzuki GSX-R. Generator removal and installation


Caution

dry these parts naturally. Do not wipe them with a cloth or use compressed air to dry.

Suzuki GSX-R. Generator removal and installation


Special tool (a): 0993044530 (rotor holder)


Tightening torque generator rotor bolt (c): 145 nm (14.5 Kgf-m, 105.0 Lbf-ft)

Suzuki GSX-R. Generator removal and installation


: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

Suzuki GSX-R. Generator removal and installation


Caution

use new gasket to prevent oil leakage.

Suzuki GSX-R. Generator removal and installation


Be careful
not to pinch the finger between the generator cover and crankcase.

 

Note

fit the clamp to the generator cover bolt c.

Suzuki GSX-R. Generator removal and installation


Generator inspection
Generator coil resistance Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .  Disconnect the generator coupler (1). Measure the re ...

Regulator / rectifier construction
Regulator/rectifier Regulator/rectifier bracket Air intake pipe (rh) Spacer Wiring harness Connect the regulator/rectifier couplers under the wiring harnes ...

Other materials:

Special tools and equipment
Recommended service material Note required service material is also described in the following. Handlebar components  steering components  steering damper construction Special tool ...

Starter motor components
O-ring Housing end (inside) O-ring Starter motor case Armature Housing end (outside) 10 Nm (1.0 Kgf-m, 7.0 Lbf-ft) 4 Nm (0.4 Kgf-m, 3.0 Lbf-ft) 5 Nm (0.5 Kgf-m, 3.5 Lbf-ft) Apply grease to sliding surface Apply moly ...

Throttle body components
Fuel delivery pipe Fuel delivery pipe t-joint O-ring Tp sensor Stp sensor Secondary fuel injector Primary fuel injector Cushion seal Isc valve Air screw Vacuum hose Evap system purge control solenoid valve For e-33 only 3.5 ...

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