Suzuki GSX-R 1000 Service Manual: Generator removal and installation
Removal
- Drain engine oil. Refer to “engine oil and filter replacement” in section 0b .
- Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .
- Disconnect the generator coupler (1).
- Remove the generator cover (2).
- Remove the gasket (3) and dowel pins.
- Hold the generator rotor with the special tool and remove the generator rotor bolt.
Special tool
(a): 09930–44530 (rotor holder)
- Screw in the special tool to the crankshaft.
- Remove the generator rotor (4) using the special tool.
Special tool
(b): 09930–30460 (rotor remover
bolt)
(c): 09930–34970 (rotor remover)
- Remove the generator stator (5).
Installation
Install the generator in the reverse order of removal. Pay attention to the following points:
- tighten the generator stator set bolts and generator lead wire set bolt to the specified torque.
Tightening torque generator stator set bolt (a): 11 n·m (1.1 Kgf-m, 8.0 Lbf-ft) generator lead wire set bolt (b): 5.5 N·m (0.55 Kgfm, 4.0 Lbf-ft)
- Apply bond lightly to the generator lead wire grommet (1).
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
- Degrease the tapered portion “a” of generator rotor and also the crankshaft “b” with nonflammable cleaning solvent.
| Caution dry these parts naturally. Do not wipe them with a cloth or use compressed air to dry. |
- Install the generator rotor onto crankshaft.
- Hold the generator rotor with the special tool and tighten its bolt to the specified torque.
Special tool
(a): 09930–44530 (rotor holder)
Tightening torque generator rotor bolt (c): 145 n·m (14.5 Kgf-m, 105.0 Lbf-ft)
- Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
- Install the dowel pins and new gasket (2).
| Caution use new gasket to prevent oil leakage. |
- Install the generator cover (3) and tighten the generator cover bolts.
 Be careful
not to pinch the finger between the generator cover and crankcase. |
| Note fit the clamp to the generator cover bolt “c”. |
- Route the generator lead wire. Refer to “wiring harness routing diagram” in section 9a .
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:
Front brake master cylinder parts inspection
Refer to “front brake master cylinder / brake lever disassembly and assembly”
.
Master cylinder
Inspect the master cylinder bore for any scratches or
other damage
Piston / rubber parts
Inspect the piston surface for any scratches or other
damage.
Inspect the primary cup, secondary cup ...
Precautions
Keep away from fire or spark.
During disassembling, use care to minimize spillage of
gasoline.
Spilled gasoline should be wiped off immediately.
Work in a well-ventilated area.
For e-33 models, drain fuel from the fuel tank before
...
Starter torque limiter removal and
installation
Removal
Remove the clutch assembly. Refer to “clutch removal” in section 5c .
Remove the washer (1), starter idle gear no. 1 (2)
And starter torque limiter (3).
Installation
Installation is in the reverse order of removal. Pay
attention to the following point:
apply ...