Suzuki GSX-R1000. Service Manual - part 25

 

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Suzuki GSX-R1000. Service Manual - part 25

 

 

1I-3 Starting System: 

Repair Instructions

Starter Motor Components

B947H11906001

1

2

3

3

5

6

4

FWD

FWD

(b)

(a)

(c)

I947H1190032-02

1. O-ring

5. Armature

: 5 N

m (0.5 kgf-m, 3.5 lbf-ft)

2. Housing end (Inside)

6. Housing end (Outside)

: Apply grease to sliding surface.

3. O-ring

: 10 N

m (1.0 kgf-m, 7.0 lbf-ft)

: Apply moly paste to sliding surface.

4. Starter motor case

: 4 N

m (0.4 kgf-m, 3.0 lbf-ft)

: Do not reuse.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Starting System:  1I-4

Starter Motor Removal and Installation

B947H11906002

Removal

1) Turn the ignition switch OFF and disconnect the 

battery (–) lead wire (1).

2) Lift and support the fuel tank. Refer to “Fuel Tank 

Removal and Installation” in Section 1G (Page 1G-
9)
.

3) Disconnect the starter motor lead wire (2).

4) Remove the starter motor (3).

Installation

Install the starter motor in the reverse order of removal. 
Pay attention to the following points:

• Apply grease to the O-ring.

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

CAUTION

!

 

Replace the O-ring with a new one.

 

• Install the starter motor. Refer to “Wiring Harness 

Routing Diagram” in Section 9A (Page 9A-7).

Starter Motor Disassembly and Assembly

B947H11906003

Refer to “Starter Motor Removal and Installation” 
(Page 1I-4)
.

Disassembly

Disassemble the starter motor as shown in the starter 
motor components diagram. Refer to “Starter Motor 
Components” (Page 1I-3)
.

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)

• Apply a small quantity of moly paste to the armature 

shaft.

:  Moly paste 99000–25140 (SUZUKI MOLY 

PASTE or equivalent)

• Fit the depression “A” on the housing end to the 

projection “B” on the case.

1

2

3

I947H1190001-02

I947H1190002-01

I947H1190004-01

I947H1190005-01

“A”

“B”

I947H1190006-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1I-5 Starting System: 

• Tighten the starter motor housing bolts (1) to the 

specified torque.

Tightening torque
Starter motor housing bolt (a):  5 N·m (0.5 kgf-m, 
3.5 lbf-ft)

Starter Motor Inspection

B947H11906004

Refer to “Starter Motor Disassembly and Assembly” 
(Page 1I-4)
.

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.

(a)

1

I947H1190007-02

“ a ”

I837H1190008-01

“A”

1

I823H1190007-01

(A)

I947H1190008-01

I947H1190009-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Starting System:  1I-6

Oil Seal

Check the seal lip for damage.
If any damage is found, replace the housing end.

Starter Relay Removal and Installation

B947H11906005

Removal

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6)
.

3) Disconnect the battery (–) lead wire (1) from the 

battery.

4) Remove the starter relay cover (2) and disconnect 

the starter relay coupler (3).

5) Disconnect the starter motor lead wire (4) and 

battery (+) lead wire (5).

6) Remove the starter relay (6).

Installation

Install the starter relay in the reverse order of removal.

Starter Relay Inspection

B947H11906006

Inspect the starter relay in the following procedures:

1) Remove the starter relay. Refer to “Starter Relay 

Removal and Installation” (Page 1I-6).

2) Apply 12 V to “A” and “B” terminals and check for 

continuity between the positive and negative 
terminals using the multi-circuit tester. If the starter 
relay clicks and continuity is found, the relay is ok.

CAUTION

!

 

Do not apply battery voltage to the starter 
relay for five seconds and more, since the 
relay coil may overheat and get damaged.

 

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity test (

)

I947H1190010-01

2

3

1

I947H1190011-03

5

6

4

I947H1190027-01

“A”

“B”

(A)

I649G1190021-04

 

“A”

“B”

To battery

To starter motor

(+)

(–)

I823H1190040-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1I-7 Starting System: 

3) Measure the relay coil resistance between the 

terminals using the multi-circuit tester. If the 
resistance is not within the specified value, replace 
the starter relay with a new one.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Starter relay resistance
3 – 6 

4) Install the starter relay. Refer to “Starter Relay 

Removal and Installation” (Page 1I-6).

Turn Signal / Side-stand Relay Removal and 
Installation

B947H11906007

Removal

1) Turn the ignition switch OFF.

2) Remove the frame cover assembly. Refer to 

“Exterior Parts Removal and Installation” in Section 
9D (Page 9D-6).

3) Remove the turn signal/side-stand relay (1).

Installation

Install the turn signal/side-stand relay in the reverse 
order of removal.

Side-stand / Ignition Interlock System Parts 
Inspection

B947H11906008

Check the interlock system for proper operation. If the 
interlock system does not operate properly, check each 
component for damage or abnormalities. If any 
abnormality is found, replace the component with a new 
one.

Side-stand Switch

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6)
.

3) Disconnect the side-stand switch coupler (1).

4) Measure the voltage between G and B/W lead wires.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Diode test (

)

NOTE

If the tester reads 1.4 V and below when the 
tester probes are not connected, replace its 
battery.

 

(A)

I649G1190023-03

1

I947H1190028-01

G

((+) probe)

B/W

((–) probe)

ON

(Side-stand up)

0.4 – 0.6 V

OFF

(Side-stand down)

1.4 V and more

(Tester’s battery voltage)

1

I947H1190012-01

I947H1190013-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Starting System:  1I-8

5) Connect the side-stand switch coupler.

6) Install the removed parts.

Turn Signal / Side-stand Relay

The turn signal/side-stand relay is composed of the turn 
signal relay, side-stand relay and diode.

Side-stand relay

1) Remove the turn signal/side-stand relay. Refer to 

“Turn Signal / Side-stand Relay Removal and 
Installation” (Page 1I-7)
.

2) Check the insulation between “D” and “E” terminals 

using the multi-circuit tester.

3) Apply 12 V to terminals “D” and “C” ((+) to “D” and (–

) to “C”) and check the continuity between “D” and 
“E”. If there is no continuity, replace the turn signal/
side-stand relay with a new one.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity test (

)

4) Install the turn signal/side-stand relay. Refer to “Turn 

Signal / Side-stand Relay Removal and Installation” 
(Page 1I-7).

Diode inspection

1) Remove the turn signal/side-stand relay. Refer to 

“Turn Signal / Side-stand Relay Removal and 
Installation” (Page 1I-7)
.

2) Measure the voltage between the “A”, “B” and “C” 

terminals using the multi-circuit tester.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Diode test (

)

NOTE

If the multi circuit tester reads 1.4 V and 
below when the tester probes are not 
connected, replace its battery.

 

3) Install the turn signal/side-stand relay. Refer to “Turn 

Signal / Side-stand Relay Removal and Installation” 
(Page 1I-7).

Gear Position Switch

1) Lift and support the fuel tank. Refer to “Fuel Tank 

Removal and Installation” in Section 1G (Page 1G-
9)
.

I649G1190027-02

DIODE

SIDE-STAND RELAY

TURN

SIGNAL

RELAY

“A”

“B”

“C”

“D”

“E”

“F”

“G”

“A”

“B” “C” “D” “E”

“F” “G”

I649G1190028-02

“A”

“B”

“C”

“A”

“B”

“C”

I649G1190029-02

+

Probe of tester to:

“A”

“A”

“C”

“B”,

“C”

“B”,

0.4

0.6 V

1.4 V and more

(Tester's battery voltage)

-

Probe of

tester to:

I649G1190046-04

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1I-9 Starting System: 

2) Disconnect the gear position switch coupler (1).

CAUTION

!

 

When disconnecting and connecting the gear 
position switch coupler, make sure to turn off 
the ignition switch, or electronic parts may 
get damaged.

 

3) Check the continuity between Bl and B lead wires 

with the transmission in “neutral”.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity test (

)

4) Connect the gear position switch coupler to the 

wiring harness.

5) Insert the needle pointed probes to the lead wire 

coupler.

6) Turn the ignition switch ON and side-stand to upright 

position.

7) Measure the voltage between P and B/W lead wires 

using the multi-circuit tester when shifting the 
gearshift lever from low to top.

Special tool

(A):  09900–25008 (Multi circuit tester set)
(B):  09900–25009 (Needle-point probe set)

Tester knob indication
Voltage (

)

Gear position switch voltage (Except neutral 
position)
0.6 V and more ((+) P – (–) B/W)

8) Turn the ignition switch OFF.

9) Install the removed parts.

Starter Torque Limiter Removal and Installation

B947H11906012

Removal

1) Remove the clutch assembly. Refer to “Clutch 

Removal” in Section 5C (Page 5C-5).

2) Remove the washer (1), starter idle gear No. 1 (2) 

and starter torque limiter (3).

Installation

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

• Apply molybdenum oil solution to the starter torque 

limiter shaft hole.

M/O:  Molybdenum oil  (MOLYBDENUM OIL 
SOLUTION)

• Install the clutch assembly. Refer to “Clutch 

Installation” in Section 5C (Page 5C-7).

1

I947H1190014-01

ON (Neutral)

OFF (Except neutral)

BI

B/W

I947H1190030-01

(A)

(B)

I947H1190015-01

1

2

3

I947H1190016-01

I947H1190017-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Starting System:  1I-10

Starter Torque Limiter Inspection

B947H11906013

Refer to “Starter Torque Limiter Removal and 
Installation” (Page 1I-9)
.

CAUTION

!

 

• Do not attempt to disassemble the starter 

torque limiter.

• The starter torque limiter is available only 

as an assembly part.

 

1) Hold the starter torque limiter with the special tools 

and vise.

Special tool

(A):  09930–73170 (Starter torque limiter 

holder)

(B):  09930–73181 (Starter torque limiter 

socket)

2) Turn the starter torque limiter with a torque wrench 

and check the slip torque. If the slip torque is not 
within the specification, replace the starter torque 
limiter with a new one.

Starter torque limiter slip torque
Standard: 20.6 – 36.3 N

m (2.06 – 3.63 kgf-m, 15.0 

– 26.0)

Starter Clutch Removal and Installation

B947H11906009

Removal

1) Remove the clutch cover. Refer to “Clutch Removal” 

in Section 5C (Page 5C-5).

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.

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)

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.

(A)

(B)

I947H1190031-01

1

2

3

I947H1190018-01

5

6

4

I947H1190019-02

(A)

7

I947H1190020-02

1

I947H1190021-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1I-11 Starting System: 

• 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)

Starter Clutch Inspection

B947H11906010

Refer to “Starter Clutch Removal and Installation” 
(Page 1I-10).

Starter Clutch

1) Install the starter driven gear onto the starter clutch.

2) Turn the starter driven gear by hand to inspect the 

starter clutch for a smooth movement. The gear 
turns in one direction only. If a large resistance is felt 
for rotation, inspect the starter clutch or the starter 
clutch contacting surface on the starter driven gear 
for wear or damage.
If they are found to be damaged, replace them with 
new ones.

Starter Clutch Bearing and Starter Driven Gear

Inspect the starter clutch bearing and starter clutch 
contacting surface on the starter driven gear for wear 
and damage. If they are found to be damaged, replace 
them with new ones.

I947H1190022-01

(A)

I947H1190023-01

I947H1190024-01

I947H1190025-02

I947H1190026-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Starting System:  1I-12

Starter Button Inspection

B947H11906011

Inspect the starter button in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner 

Box Removal and Installation” in Section 1D 
(Page 1D-7).

2) Disconnect the right handlebar switch coupler (1).

3) Inspect the starter button for continuity with the 

tester.
If any abnormality is found, replace the right handle 
switch assembly with a new one. Refer to 
“Handlebar Removal and Installation” in Section 6B 
(Page 6B-2).

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity (

)

4) After finishing the starter button inspection, reinstall 

the removed parts.

Specifications

Service Data

B947H11907001

Electrical

Unit: mm

Tightening Torque Specifications

B947H11907002

NOTE

The specified tightening torque is described in the following.
“Starter Motor Components” (Page 1I-3)

 

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C 
(Page 0C-9)
.

1

I947H1190029-01

Position

Color

PUSH

O/W

Y/G

O/R

Y/W

I815H1190019-01

Item

Specification

Note

Starter motor brush length

Standard

7.0 (0.28)

Limit

3.5 (0.14)

Starter relay resistance

3 – 6 

Fastening part

Tightening torque

Note

N

m

kgf-m

lbf-ft

Starter motor housing bolt

5

0.5 

3.5 

)

(Page 1I-5)

Starter clutch bolt

54

5.4 

39.0 

)

(Page 1I-11)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1I-13 Starting System: 

Special Tools and Equipment

Recommended Service Material

B947H11908001

NOTE

Required service material is also described in the following.
“Starter Motor Components” (Page 1I-3)

 

Special Tool

B947H11908002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or 
equivalent

P/No.: 99000–25010

)

(Page 1I-4) / 

)

(Page 1I-4)

Moly paste

SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140

)

(Page 1I-4)

Molybdenum oil

MOLYBDENUM OIL SOLUTION

)

(Page 1I-9) / 

)

(Page 1I-

11)

09900–20102

09900–25008

Vernier calipers (200 mm)

Multi circuit tester set

)

(Page 1I-5)

)

(Page 1I-5) / 

)

(Page 1I-6) 

)

(Page 1I-7) / 

)

(Page 1I-

7) / 

)

(Page 1I-8) / 

)

(Page 1I-8) / 

)

(Page 1I-9) 

)

(Page 1I-9) / 

)

(Page 1I-

12)

09900–25009

09930–40113

Needle-point probe set

Flywheel rotor holder

)

(Page 1I-9)

)

(Page 1I-10) / 

)

(Page 1I-

11)

09930–73170

09930–73181

Starter torque limiter holder

Starter torque limiter socket

)

(Page 1I-10)

)

(Page 1I-10)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Charging System:  1J-1

Engine

Charging System

Schematic and Routing Diagram

Charging System Diagram

B947H11A02001

Component Location

Charging System Components Location

B947H11A03001

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

Diagnostic Information and Procedures

Charging System Symptom Diagnosis

B947H11A04001

SCR

IC

Generator

Regulator/Rectifier

Ignition switch

Batter

y

Load

I947H11A0021-01

Condition

Possible cause

Correction / Reference Item

Generator does not 
charge

Open- or short-circuited lead wires, or 
loose lead connections.

Repair, replace or connect properly.

Short-circuited, grounded or open 
generator coil.

Replace.

Short-circuited or punctured regulator/
rectifier.

Replace.

Generator does charge, 
but charging rate is below 
the specification

Lead wires tend to get short- or open-
circuited or loosely connected at 
terminals.

Repair or retighten.

Grounded or open-circuited generator 
coil.

Replace.

Defective regulator/rectifier.

Replace.

Defective cell plates in the battery.

Replace the battery.

Generator overcharges

Internal short-circuit in the battery.

Replace the battery.

Damaged or defective regulator/rectifier.

Replace.

Poorly grounded regulator/rectifier.

Clean and tighten ground connection.

Unstable charging

Lead wire insulation frayed due to 
vibration, resulting in intermittent short-
circuiting.

Repair or replace.

Internally short-circuited generator.

Replace.

Defective regulator/rectifier.

Replace.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1J-2 Charging System: 

Battery Runs Down Quickly

B947H11A04002

Troubleshooting

Battery overcharges

Faulty regulator/rectifier.

Replace.

Faulty battery.

Replace.

Poor contact of generator lead wire 
coupler.

Repair.

Battery runs down quickly

Trouble in charging system.

Check the generator, regulator/rectifier and 
circuit connections and make necessary 
adjustments to obtain specified charging 
operation.

Cell plates have lost much of their active 
materials a result of overcharging.

Replace the battery and correct the charging 
system.

Internal short-circuit in the battery.

Replace the battery.

Too low battery voltage.

Recharge the battery fully.

Too old battery.

Replace the battery.

Battery “sulfation”

Incorrect charging rate. (When not in 
use battery should be checked at least 
once a month to avoid sulfation.)

Replace the battery.

The battery was left unused in a cold 
climate for too long.

Replace the battery if badly sulfated.

Condition

Possible cause

Correction / Reference Item

Step

Action

Yes

No

1

Check accessories which use excessive amounts of 
electricity.

Are accessories being installed?

Remove accessories.

Go to Step 2.

2

Check the battery for current leakage. Refer to “Battery 
Current Leakage Inspection” (Page 1J-3)
.

Is the battery for current leakage OK?

Go to Step 3.

• Short circuit of wire 

harness.

• Faulty electrical 

equipment.

3

Measure the regulated voltage between the battery 
terminals. Refer to “Regulated Voltage Inspection” (Page 1J-
3).

Is the regulated voltage OK?

• Faulty battery.

• Abnormal driving 

condition.

Go to Step 4.

4

Measure the resistance of the generator coil. Refer to 
“Generator Inspection” (Page 1J-3).

Is the resistance of generator coil OK?

Go to Step 5.

• Faulty generator coil.

• Disconnected lead 

wires.

5

Measure the generator no-load performance. Refer to 
“Generator Inspection” (Page 1J-3).

Is the generator no-load performance OK?

Go to Step 6.

Faulty generator.

6

Inspect the regulator/rectifier. Refer to “Regulator / Rectifier 
Inspection” (Page 1J-8).

Is the regulator/rectifier OK?

Go to Step 7.

Faulty regulator/rectifier.

7

Inspect wirings.

Is the wirings OK?

Faulty battery.

• Short circuit of wire 

harness.

• Poor contact of 

couplers.

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Charging System:  1J-3

Repair Instructions

Battery Current Leakage Inspection

B947H11A06001

Inspect the battery current leakage in the following 
procedures:

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6)
.

3) Disconnect the battery (–) lead wire.

4) Measure the current between battery (–) terminal 

and the battery (–) lead wire using the multi-circuit 
tester. If the reading exceeds the specified value, 
leakage is evident.

CAUTION

!

 

• In case of a large current leak, turn the 

tester to high range first to avoid tester 
damage.

• Do not turn the ignition switch ON when 

measuring current.

 

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Current (

, 20 mA)

Battery current (Leak)
Under 3 mA

5) Connect the battery (–) terminal and install the front 

seat. Refer to “Battery Removal and Installation” 
(Page 1J-11)
 and “Exterior Parts Removal and 
Installation” in Section 9D (Page 9D-6).

Regulated Voltage Inspection

B947H11A06002

Inspect the regulated voltage in the following 
procedures:

1) Remove the front seat. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6)
.

2) Start the engine and keep it running at 5 000 r/min 

with the dimmer switch turned HI position.

3) Measure the DC voltage between the battery (+) and 

(–) terminals using the multi-circuit tester. If the 
voltage is not within the specified value, inspect the 
generator and regulator/rectifier. Refer to “Generator 
Inspection” (Page 1J-3) an
d “Regulator / Rectifier 
Inspection” (Page 1J-8).

NOTE

When making this test, be sure that the 
battery is in fully charged condition.

 

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Voltage (

)

Regulated voltage (Charging output)
Standard: 14.0 – 15.5 V at 5 000 r/min

4) Install the front seat. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6)
.

Generator Inspection

B947H11A06003

Generator Coil Resistance

1) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6)
.

2) Disconnect the generator coupler (1).

(A)

I837H11A0025-01

(DCV)

Tester

Battery

(A)

I837H11A0026-01

1

I947H11A0001-01

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1J-4 Charging System: 

3) Measure the resistance between the three lead 

wires.
If the resistance is out of specified value, replace the 
stator with a new one. Also, check that the generator 
core is insulated properly.

NOTE

When making this test, be sure that the 
battery is in fully charged condition.

 

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Resistance (

)

Generator coil resistance
0.12 – 0.6 

 (W – W)

 

 (W – Ground)

4) Connect the generator coupler.

5) Install the left side cowling. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6).

No-load Performance

1) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6).

2) Disconnect the generator coupler (1).

3) Start the engine and keep it running at 5 000 r/min.

4) Using the multi-circuit tester, measure the voltage 

between three lead wires.
If the tester reads under the specified value, replace 
the generator with a new one.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Voltage (~)

Generator no-load performance (When engine is 
cold)
85 V (AC) and more at 5 000 r/min

5) Connect the generator coupler.

6) Install the left side cowling. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6).

Generator Removal and Installation

B947H11A06004

Removal

1) Drain engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

2) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6)
.

3) Disconnect the generator coupler (1).

4) Remove the generator cover (2).

W

W

W

I947H11A0002-02

1

I947H11A0003-01

W

W

W

I947H11A0004-02

1

I947H11A0005-01

2

I947H11A0006-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Charging System:  1J-5

5) Remove the gasket (3) and dowel pins.

6) Hold the generator rotor with the special tool and 

remove the generator rotor bolt.

Special tool

(A):  09930–44530 (Rotor holder)

7) Screw in the special tool to the crankshaft.

8) Remove the generator rotor (4) using the special 

tool.

Special tool

(B):  09930–30460 (Rotor remover bolt)
(C):  09930–34970 (Rotor remover)

9) Remove the generator stator (5).

Installation

Install the generator in the reverse order of removal. Pay 
attention to the following points:

• Tighten the generator stator set bolts and generator 

lead wire set bolt to the specified torque.

Tightening torque
Generator stator set bolt (a):  11 N·m (1.1 kgf-m, 
8.0 lbf-ft)
Generator lead wire set bolt (b):  5.5 N·m (0.55 kgf-
m, 4.0 lbf-ft)

• Apply bond lightly to the generator lead wire grommet 

(1).

:  Sealant 99000–31140 (SUZUKI BOND 

No.1207B or equivalent)

3

I947H11A0007-01

(A)

I947H11A0008-01

(C)

4

(B)

I947H11A0009-03

(C)

(B)

I947H11A0022-02

5

I947H11A0010-01

(b)

(a)

1

I947H11A0011-03

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