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:

Rear brake light switch inspection
Inspect the rear brake light switch in the following procedures: lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). Disconnect the rear brake light switch lead wire coupler (1). Inspect the rear brake light swi ...

Rear brake caliper removal and installation
Removal Remove the rear wheel. Refer to “rear wheel assembly removal and installation” in section 2d . Drain brake fluid. Refer to “brake fluid replacement” in section 4a . Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a ...

Lower light bulb
Turn the socket 1 counterclockwise and remove it. Turn the socket 2 counterclockwise and remove it. Remove the bulb 3 from the socket. Caution Oil from your skin may damage the headlight bulb or shorten its life. Grasp the new bulb with a c ...