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).

4. Remove the generator cover (2).

5. Remove the gasket (3) and dowel pins.

6. Hold the generator rotor with the special tool and remove the generator rotor bolt.

Special tool (a): 09930–44530 (rotor holder)

7. Screw in the special tool to the crankshaft.
8.  Remove the generator rotor (4) using the special tool.

Special tool (b): 09930–30460 (rotor remover
bolt) (c): 09930–34970 (rotor remover)

9. Remove the generator stator (5).

Installation

Install the generator in the reverse order of removal. Pay attention to the following points:

•  tighten the generator stator set bolts and generator lead wire set bolt to the specified torque.

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)

• Apply bond lightly to the generator lead wire grommet (1).

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

• Degrease the tapered portion “a” of generator rotor and also the crankshaft “b” with nonflammable cleaning solvent.

• Install the generator rotor onto crankshaft.

• Hold the generator rotor with the special tool and tighten its bolt to the specified torque.

Special tool (a): 09930–44530 (rotor holder)

Tightening torque generator rotor bolt (c): 145 n·m (14.5 Kgf-m, 105.0 Lbf-ft)

• Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

• Install the dowel pins and new gasket (2).

• Install the generator cover (3) and tighten the generator cover bolts.

Be careful not to pinch the finger between the generator cover and crankcase.

• Route the generator lead wire. Refer to “wiring harness routing diagram” in section 9a .