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

Apply a small quantity of moly paste to the armature shaft.

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

Suzuki GSX-R. Starter motor disassembly and assembly

Fit the depression “a” on the housing end to the projection “b” on the case.

Suzuki GSX-R. Starter motor disassembly and assembly

Tighten the starter motor housing bolts (1) to the specified torque.

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:

Light bulb replacement
The wattage rating of each bulb is shown in the following chart. When replacing a burned-out bulb, always use the same wattage rating according to the following chart. Caution Using a light bulb with the wrong wattage rating can cause electrical system damage or shorte ...

Fuel tank removal and installation
Removal Keep away from fire or spark. Spilled gasoline should be wiped off immediately. Work in a well-ventilated area. Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Take ...

Ap sensor removal and installation
Removal Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Disconnect the starter relay (1) from the holder. Disconnect the coupler (2) and remove the ap sensor (3). Installation Install the ap sensor in the rever ...