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:
Turn signal / side-stand relay removal and
installation
Removal
Turn the ignition switch off.
Remove the frame cover assembly. Refer to “exterior parts removal and
installation” in section 9d .
Remove the turn signal/side-stand relay (1).
Installation
Install the turn signal/side-stand relay in the reverse
order of removal ...
Engine coolant temperature indicator light inspection
Inspect the engine coolant temperature meter and indicator light (led) in the
following procedures:
remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the ect sensor coupler (1).
Connect a variable resistor (2) ...
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, replace the brush
holder set with a new one.
Measure the length “a” of the carbon brushes using a
v ...