Suzuki GSX-R 1000 Service Manual: Starter torque limiter inspection

Suzuki GSX-R 1000 Service Manual / Engine / Starting system / Repair instructions / 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).

Suzuki GSX-R. Starter torque limiter inspection

Remove the starter idle gear no. 2 Bearing (4), shaft (5) and washer (6).

Suzuki GSX-R. Starter torque limiter inspection

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.

Suzuki GSX-R. Starter torque limiter inspection

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

install the washer (1) to the crankshaft.

Suzuki GSX-R. Starter torque limiter inspection

When installing the starter clutch and ckp sensor rotor, align the wide spline tooth of them with that of crankshaft.

Suzuki GSX-R. Starter torque limiter inspection

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)

Suzuki GSX-R. Starter torque limiter inspection

Apply molybdenum oil solution to the starter idle gear no. 2 Bearing, shaft and shaft hole.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Starter torque limiter inspection

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:

Iat sensor inspection
Refer to “dtc “c21” (p0110-h/l): iat sensor circuit malfunction” in section 1a . Inspect the iat sensor. Note iat sensor resistance measurement method is the same way as that of the ect sensor. Refer to “ect sensor inspection” (page 1c- 4). Caution & ...

Clutch control system components
Push rod Clutch release camshaft Clutch release arm Clutch cable 1 N·m (0.1 Kgf-m, 0.7 Lbf-ft) 6 N·m (0.6 Kgf-m, 4.5 Lbf-ft) 10 N·m (1.0 Kgf-m, 0.7 Lbf-ft) Apply grease Do not reuse. ...

DTC “c12” (p0335): ckp sensor circuit malfunction.
Detected condition and possible cause Detected condition Possible cause The signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Metal particles or foreign material being stuck on the ckp sensor and rotor tip. Ckp ...