Suzuki GSX-R 1000 Service Manual: 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:
| Caution replace the o-rings with new ones to prevent oil leakage and moisture. |
Apply grease to the bearing and lip of the oil seal.
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Apply a small quantity of moly paste to the armature shaft.
: Moly paste 99000–25140 (suzuki moly paste or equivalent)
- Fit the depression “a” on the housing end to the projection “b” on the case.
- Tighten the starter motor housing bolts (1) to the specified torque.
Tightening torque starter motor housing bolt (a): 5 n·m (0.5 Kgf-m, 3.5 Lbf-ft)
Starter motor removal and installation
Removal
Turn the ignition switch off and disconnect the
battery (–) lead wire (1).
Lift and support the fuel tank. Refer to “fuel tank
removal and installation” in section 1g (page 1g- ...
Starter motor inspection
Refer to “starter motor disassembly and assembly” .
Carbon brush
Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If either carbon brush is defective, repl ...
Other materials:
Ect sensor inspection
Refer to “dtc “c15” (p0115-h/l): ect sensor circuit malfunction” in section
1a .
Inspect the ect sensor in the following procedures:
remove the ect sensor. Refer to “ect sensor removal and installation” .
Connect the ect sensor (1) to the circuit tester and
place it in the o ...
Ignition switch
The ignitionr switch has 4 positions:
"Off" position
All electrical circuits are cut off.
The engine will not start. The key
can be removed.
"On" position
The ignition circuit is completed
and the engine can run. The
headlight and taillight will automatically
turn ...
Headlight
To replace the headlight bulbs,
perform the following steps:
Upper light bulb
Remove the bolt 1 to lift the
instrument panel 2.
Turn the cap 3 counterclockwise
and remove it.
Unhook the bulb holder spring
4 and pull out the socket 5.
Pull off the bulb from ...