Suzuki GSX-R 1000 Service Manual: Starter torque limiter inspection
Removal
- Remove the clutch cover. Refer to “clutch removal” in section 5c .
- Remove the washers (1), starter idle gear no. 1 (2) And no. 2 (3).
- Remove the starter idle gear no. 2 Bearing (4), shaft (5) and washer (6).
- Hold the starter clutch with the special tool and remove the starter clutch bolt.
| Caution make sure that the pawls of the special tool are inserted into the holes of the starter clutch. |
Special tool
(a): 09930–40113 (flywheel rotor
holder)
- Remove the ckp sensor rotor (7) and starter clutch assembly.
Installation
Installation is in the reverse order of removal. Pay attention to the following points:
- install the washer (1) to the crankshaft.
- When installing the starter clutch and ckp sensor rotor, align the wide spline tooth of them with that of crankshaft.
- Hold the starter clutch with the special tool and tighten the starter clutch bolt to the specified torque.
Special tool
(a): 09930–40113 (flywheel rotor
holder)
Tightening torque starter clutch bolt: 54 n·m (5.4 Kgf-m, 39.0 Lbf-ft)
- Apply molybdenum oil solution to the starter idle gear no. 2 Bearing, shaft and shaft hole.
M/o: molybdenum oil (molybdenum oil solution)
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
Inst ...
Starter clutch inspection
Refer to “starter clutch removal and installation” .
Starter clutch
Install the starter driven gear onto the starter clutch.
Turn the starter driven gear by hand to inspect the
starter ...
Other materials:
Handlebar components
Throttle grip
Grip rubber
Right handlebar switch box
Left handlebar switch box
Right handlebar
Left handlebar
Handlebar expander
Handlebar balancer
Apply handle grip bond.
23
N·m (2.3 Kgf-m, 16.5 Lbf-ft)
5.5 N·m
(0.55 Kgf-m, 4.0 L ...
Rear brake hose routing diagram
Hose clamp
: face the clamp end backward.
Stopper
: after the brake hose union has contacted
to the stopper, tighten the union bolt.
Brake pad pin
Plug
Caliper sliding pin b
Caliper sliding pin a
White marking
Yellow marking
Pass the
...
Side-stand / ignition interlock system parts
inspection
Check the interlock system for proper operation. If the
interlock system does not operate properly, check each
component for damage or abnormalities. If any
abnormality is found, replace the component with a new
one.
Side-stand switch
Turn the ignition switch off.
Remove the left si ...