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Suzuki GSX-R 1000 Service Manual: Starter motor disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Engine / Starting system / Repair instructions / Starter motor disassembly and assembly

Refer to “starter motor removal and installation” .

Disassembly

Disassemble the starter motor as shown in the starter motor components diagram. Refer to “starter motor components” .

Assembly

Reassemble the starter motor in the reverse order of removal. Pay attention to the following points:

Caution

replace the o-rings with new ones to prevent oil leakage and moisture.

Apply grease to the bearing and lip of the oil seal.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Starter motor disassembly and assembly


: Moly paste 99000–25140 (suzuki moly paste or equivalent)

Suzuki GSX-R. Starter motor disassembly and assembly


Suzuki GSX-R. Starter motor disassembly and assembly


Tightening torque starter motor housing bolt (a): 5 n·m (0.5 Kgf-m, 3.5 Lbf-ft)

Suzuki GSX-R. Starter motor disassembly and assembly


Starter motor removal and installation
Removal Turn the ignition switch off and disconnect the battery (–) lead wire (1).  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- ...

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, repl ...

Other materials:

Engine bottom side disassembly
Note the crankcase must be separated to service the crankshaft and conrod. Remove the engine assembly from the frame. Refer to “engine assembly removal” .  Remove the engine top side (1). Refer to “engine top side disassembly” . Crankcase breather (pcv) cover R ...

Steering tension adjustment
Check the steering movement in the following procedures:  by supporting the motorcycle with a jack, lift the front wheel unit is off the floor 20 – 30 mm (0.8 – 1.2 In).  Remove the steering damper. Refer to “steering damper construction” .  Check to make sure that the cabl ...

Excva removal and installation
Removal Turn the ignition switch off.  Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Connect the special tool (mode select switch) to the dealer mode coupler. Refer to “self-diagnostic procedures” in section 1a . After tur ...

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