Toyota RAV4 manuals

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))

Suzuki GSX-R. Starter motor inspection


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.

Suzuki GSX-R. Starter motor inspection


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 ( )


Suzuki GSX-R. Starter motor inspection


Bearing

Check the bearings for damage.

If any damage is found, replace the housing end.

Suzuki GSX-R. Starter motor inspection


Oil seal

Check the seal lip for damage.

If any damage is found, replace the housing end.

Suzuki GSX-R. Starter motor inspection


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 Rea ...

Starter relay removal and installation
Removal Turn the ignition switch off.  Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Disconnect the battery (–) lead wire ...

Other materials:

Starting the engine
Before attempting to start the engine, make sure:  The transmission is in neutral.  The engine stop switch is in the "" position. Note: this motorcycle has a starter interlock system for the ignition and starter circuit. The engine can only be started if:   ...

Regulator / rectifier construction
Regulator/rectifier Regulator/rectifier bracket Air intake pipe (rh) Spacer Wiring harness Connect the regulator/rectifier couplers under the wiring harness 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) ...

Fuel tank removal and installation
Removal Keep away from fire or spark.  Spilled gasoline should be wiped off immediately.  Work in a well-ventilated area. Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Take ...

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