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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:

Fail-safe function table
Fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. The engine can start and can run even if the signal in the table is not received from each sensor. But, the engine ...

Rear wheel components
Rear axel nut Collar Dust seal Bearing Retainer Rear sprocket Sprocket mounting drum Wheel damper Bearing Spacer Air valve Rear wheel Wheel balancer Rear tire Dust seal Collar Rear brake disc Rear axle 1 ...

Precautions
Precautions for engine cooling system You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pr ...

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