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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:

Gearshift linkage inspection
Refer to gearshift shaft / gearshift cam plate removal and installation . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...

Air cleaner element removal and installation
Removal Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).  Remove the air cleaner box cover (1). Remove the air cleaner element (2). Installation Installation is in the reverse order of removal. ...

Starter motor disassembly and assembly
Refer to starter motor removal and installation . Disassembly Disassemble the starter motor as shown in the starter motor components diagram. Refer to starter motor components . Assembly Reassemble the starter motor in the reverse order of removal. Pay attention to the following points: ...

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