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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:

Drive chain inspection and adjustment
Inspect drive chain initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Drive chain visual check With the transmission in neutral, support the motorcycle using a jack and turn the rear wheel slowly by hand. Visually check the drive chain fo ...

Specifications
Tightening torque specifications Note the specified tightening torque is described in the following. “Chassis bolt and nut inspection” Reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c . ...

Wheel / tire / air valve inspection and cleaning
Refer to “tire removal and installation” . Wheel Wipe the wheel clean and check for the following points:  distortion and crack  any flaws and scratches at the bead seating area.  Wheel rim runout. Refer to “front wheel related parts inspection”  and “rear wheel rela ...

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