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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): 09930–44530 (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): 09930–30460 (rotor remover
bolt) (c): 09930–34970 (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 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)

: Sealant 99000–31140 (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): 09930–44530 (rotor holder)


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

Suzuki GSX-R. Generator removal and installation


: Sealant 99000–31140 (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:

Specifications
Service data Fi sensors Tightening torque specifications Note the specified tightening torque is described in the following. “Exhaust control system construction”  “exhaust system components” Reference: for the tightening torque of fastener not specified in this ...

Precautions
Precautions for engine electrical device Refer to “general precautions” in section 00 (page 00-1) and “precautions for electrical circuit service” in section 00 (page 00-2). Component location Engine electrical components location Refer to “electrical components location” in section 0a . Dia ...

Tightening torque list
Engine Fi system + intake air system Cooling system Chassis Tightening torque chart For other bolts and nuts not listed in the preceding page, refer to this chart: Conventional bolt “4” Marked bolt “7” Marked bolt ...

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