Overhaul

Starting Motor Disassembly and Reassembly

Disassembly

Starting Motor Removal and Installation

Starting Motor Components
1) Before disassembly, draw alignment mark (1) and (2) for easy correct positioning on reassembly.





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





3) Remove screws (4) and take out magnetic switch (1), and then disassemble spring (2) and plunger (3).

NOTE:
Do not disassemble magnetic switch. Replace it as assembly, if necessary.





4) Remove bolts (1), then separate yoke from starter housing (2).





5) Remove packing (2) and planetary gears (1).





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





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





8) Draw pinion stop ring (3) toward over-running clutch side and remove snap ring (2) by using snap ring pliers (5), then pull out pinion stop ring (3), over-running clutch (4) and internal gear (1) from gear shaft.





9) Remove starter end frame (1), and then remove brush assembly (2) from yoke (3).





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





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






Reassembly

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





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





4) Install starter end frame (1) to brush holder. 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 over-running 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 over-running clutch (1) to gear shaft (4) with new snap ring (3) noting the direction of pinion stop ring (2).





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

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





8) Install packing (1) so that cuts in packing align with holes (3) for through bolts in starter housing.
9) Install plate (5) and seal rubber (4) to starter housing.
10) Apply grease to planetary gears (2), then Install planetary gears to gear shaft.

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





11) Install yoke, armature, brush assembly and starter end frame (4) to starter housing (2) by aligning with alignment mark (3) provided before disassembly.
12) Tighten starter end frame bolts (1) to specified torque.

Tightening torque
End frame 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 starter housing (5) by aligning match marks provided before removal, and then tighten screws (4) to specified torque.

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





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

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





16) After completing assembly, check magnetic switch for operation.