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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


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

Suzuki GSX-R. Starter motor disassembly and assembly


Suzuki GSX-R. Starter motor disassembly and assembly


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:

Throttle body disassembly and assembly
Refer to “throttle body removal and installation” . Disassembly Caution identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. Disconnect the fuel feed hose (1), isc valve ho ...

Cushion rod inspection
Refer to “cushion rod removal and installation” . Collar and spacer Remove the collar and spacer from the cushion rod.  Inspect the collar and spacer for any flaws or other damage. If any defects are found, replace it with a new one. Cushion rod bearing Insert the collar a ...

Rear brake light switch inspection and adjustment
Check the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. If the brake light switch adjustment is necessary, turn the adjuster nut (1) in or out while holding the brake pedal. Brake fluid level check Refer to “bra ...

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