Suzuki GSX-R 1000 Service Manual: 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, replace the brush holder set with a new one.

Measure the length “a” of the carbon brushes using a vernier calipers. If the measurement is less than the service limit, replace the housing end assembly (outside) with a new one.

Brush length “a” service limit: 3.5 Mm (0.14 In)

Special tool : 09900–20102 (vernier calipers
(200 mm))

Commutator

Inspect the commutator for discoloration, abnormal wear or undercut “a”.

If the commutator is abnormally worn, replace the armature assembly.

If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.

If there is no undercut, scrape out the insulator (1) with a saw blade.

Armature coil

Inspect for continuity between each segment.

Inspect for continuity between each segment and the armature shaft.

If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature assembly with a new one.

Special tool (a): 09900–25008 (multi circuit
tester set)

Tester knob indication continuity set ( )

Bearing

Check the bearings for damage.

If any damage is found, replace the housing end.

Oil seal

Check the seal lip for damage.

If any damage is found, replace the housing end.