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Starting Motor Reassembly

CAUTION:
  • Washing, adjusting and disassembling of shock absorber (clutch plate) are not allowed.
  • New oilless bearing have been lubricated when they are supplied as spare parts. DO NOT wash with grease dissolving solvent nor lubricate them with other lubricant.
  1. Inspect component parts (Refer to "STARTING MOTOR INSPECTION " and replace with new ones as necessary.
  2. Apply grease (Refer to "STARTING MOTOR DESCRIPTION ".)
  3. Install armature to yoke.
  4. Install brushes (1) and brush springs (2) to brush holder (3).
  5. Install brush holder (3) to armature while pushing 4 brushes (1) outward.
    Fig 1: Installing Brush Holder To Armature
    G04098230Courtesy of SUZUKI OF AMERICA CORP.
  6. Install rear bush and then rear bracket cap.
  7. Install rear bracket (1).
  8. Tighten brush holder screws (2).
    Fig 2: Installing Rear Bracket
    G04098231Courtesy of SUZUKI OF AMERICA CORP.
  9. Install over-running clutch assembly (1) to gear shaft (4), using care for installing direction of pinion stop ring (2).
    Fig 3: Installing Over-Running Clutch Assembly To Gear Shaft
    G04098232Courtesy of SUZUKI OF AMERICA CORP.
  10. Insert shaft assembly (1) into front housing with lever (2) positioned as shown in the figure.
    Fig 4: Inserting Shaft Assembly Into Front Housing
    G04098233Courtesy of SUZUKI OF AMERICA CORP.
  11. Install packing (1) so that cuts in packing align with holes for through bolts in front housing.
  12. Install plate and seal rubber (4) to front housing.
    Fig 5: Installing Plate And Seal Rubber To Front Housing
    G04098234Courtesy of SUZUKI OF AMERICA CORP.
  13. Apply grease to ball (1) and install ball (1) into shaft hole.
    Fig 6: Installing Ball Into Shaft Hole
    G04098235Courtesy of SUZUKI OF AMERICA CORP.
  14. Install yoke, armature, brush holder and rear bracket to front housing (2) by aligning match marks provided before removal.
  15. Tighten through bolts (1).
    Fig 7: Installing Yoke, Armature, Brush Holder And Rear Bracket To Front Housing
    G04098236Courtesy of SUZUKI OF AMERICA CORP.
  16. Install magnetic switch assembly (1) and protector (2) (if equipped). Connect wire (switch to motor) to switch terminal.
    Fig 8: Installing Magnetic Switch Assembly And Protector
    G04098237Courtesy of SUZUKI OF AMERICA CORP.
  17. Upon completion of assembly, carry out performance test. Refer to "STARTING MOTOR PERFORMANCE TEST ".
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