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Suzuki GSX-R 1000 Service Manual: Starter torque limiter inspection

Removal

  1. Remove the clutch cover. Refer to “clutch removal” in section 5c .
  2.  Remove the washers (1), starter idle gear no. 1 (2) And no. 2 (3).

Suzuki GSX-R. Starter torque limiter inspection


  1. Remove the starter idle gear no. 2 Bearing (4), shaft (5) and washer (6).

Suzuki GSX-R. Starter torque limiter inspection


  1. Hold the starter clutch with the special tool and remove the starter clutch bolt.
Caution

make sure that the pawls of the special tool are inserted into the holes of the starter clutch.

Special tool (a): 09930–40113 (flywheel rotor
holder)

  1. Remove the ckp sensor rotor (7) and starter clutch assembly.

Suzuki GSX-R. Starter torque limiter inspection


Installation

Installation is in the reverse order of removal. Pay attention to the following points:

Suzuki GSX-R. Starter torque limiter inspection


Suzuki GSX-R. Starter torque limiter inspection


Special tool (a): 09930–40113 (flywheel rotor
holder)

Tightening torque starter clutch bolt: 54 n·m (5.4 Kgf-m, 39.0 Lbf-ft)

Suzuki GSX-R. Starter torque limiter inspection


M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Starter torque limiter inspection


Starter torque limiter removal and installation
Removal Remove the clutch assembly. Refer to “clutch removal” in section 5c .  Remove the washer (1), starter idle gear no. 1 (2) And starter torque limiter (3). Installation Inst ...

Starter clutch inspection
Refer to “starter clutch removal and installation” . Starter clutch Install the starter driven gear onto the starter clutch.  Turn the starter driven gear by hand to inspect the starter ...

Other materials:

Water pump removal and installation
Removal Note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, visually inspect the mechanical seal and s ...

Balancer shaft journal bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. Selection Place the plastigauge axial ...

Rear shock absorber disposal
Refer to “rear shock absorber removal and installation” . The rear shock absorber unit contains high-pressure nitrogen gas. Mishandling can cause explosion.  Keep away from fire and heat. High gas pressure caused by heat can cause an explosion.  Release gas ...

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