Overhaul

Starting Motor Disassembly and Reassembly

Disassembly

Starting Motor Removal and Installation

Starting Motor Components
1) Before disassembly, draw matchmarks (1) and (2) shown in figure, in order to make it easier to reassemble components in the correct position.





2) Remove nut (1) and disconnect lead wire (2) from magnetic switch (3).





3) Remove screws (4) and pull out magnetic switch (1) from starting motor assembly.
4) Disassemble spring (2) and plunger (3) from magnetic switch body





5) Remove bolts (1) and separate yoke from armature housing (2).





6) Remove grommet (2) and planetary gears (1).





7) Remove seal rubber (1) and plate (2).





8) Remove shaft assembly (1) with drive lever (2).





9) With pinion stop ring (3) moved to overrunning clutch (4) side (arrow side), remove snap ring (2) by using snap ring pliers (5).
10) Remove pinion stop ring (3), overrunning clutch (4) and internal gear (1) from gear shaft.





11) Remove end housing (1) and remove brush assembly (2) from yoke (3).





12) Remove armature (1) from yoke (2).





13) Remove brushes (1) and brush springs (2).






Reassembly

Starting Motor Inspection
1) Install brush springs (2) and brushes (1) to brush holder (3).





2) Install armature (2) to yoke.
3) Install brush assembly (1) to armature (2) while pushing 4 brushes (3) outward.





4) Install end housing (1) to brush holder and tighten brush holder screws (2) to specified torque.

Tightening torque
Brush holder screw (a): 3.5 Nm (0.36 kgf-m, 3.0 lbf-ft)





5) Before installing overrunning clutch (2) and internal gear (3) to gear shaft (1), apply grease to shaft spline.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)





6) Install internal gear and overrunning clutch (1) to gear shaft (4) with new snap ring (3) and pinion stop ring (2).

NOTE:
Install pinion stop ring in the direction and position as shown in figure.





7) Apply grease to drive lever (2) and insert shaft assembly (1) into armature housing with drive lever positioned as shown in the figure.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)





8) With armature housing bolt holes (3) and grommet cutting positions aligned, install grommet (1) in armature housing.
9) Install plate (5) and seal rubber (4) to armature housing.
10) Apply grease to planetary gears (2) and install planetary gears to gear shaft.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)





11) Install yoke, armature, brush assembly and end housing (4) to armature housing (2) in alignment with matchmarks (3) drawn before disassembly.
12) Tighten end housing bolts (1) to specified torque.

Tightening torque
End housing bolt (a): 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)





13) Apply grease to plunger.

"A" Grease: 99000-25011 (SUZUKI Super Grease A)





14) Install magnetic switch (1), spring (2) and plunger (3) to armature housing (5) in alignment with matchmark drawn before removal.
15) Tighten screws (4) to specified torque.

Tightening torque
Magnetic switch screw (a): 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)





16) Connect lead wire (1) to terminal "M" (2) and tighten lead wire nut to specified torque.

Tightening torque
Lead wire nut (a): 10 Nm (1.0 kgf-m, 7.5 lbf-ft)





17) Check magnetic switch for operation. Starting Motor Inspection