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).

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

4. Hold the starter clutch with the special tool and remove the starter clutch bolt.

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

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

Installation

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

•  install the washer (1) to the crankshaft.

• When installing the starter clutch and ckp sensor rotor, align the wide spline tooth of them with that of crankshaft.

• Hold the starter clutch with the special tool and tighten the starter clutch bolt to the specified torque.

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

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

• Apply molybdenum oil solution to the starter idle gear no. 2 Bearing, shaft and shaft hole.

M/o: molybdenum oil (molybdenum oil solution)