Starting Motor Reassembly

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING

Reference: STARTING MOTOR DISASSEMBLY

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.

Inspect component parts (Refer to STARTING MOTOR INSPECTION and replace with new ones as necessary.
Apply grease (Refer to STARTING MOTOR DESCRIPTION .)
Install armature to yoke.
Install brushes (1) and brush springs (2) to brush holder (3).
Install brush holder (3) to armature while pushing 4 brushes (1) outward.

Fig 1: Identifying Brushes, Brush Springs & Brush Holder
Courtesy of SUZUKI OF AMERICA CORP.
Install rear bush and then rear bracket cap.
Install rear bracket (1).
Tighten brush holder screws (2).

Fig 2: Identifying Rear Bracket & Brush Holder Screws
Courtesy of SUZUKI OF AMERICA CORP.
Install over-running clutch assembly (1) to gear shaft (4), using care for installing direction of pinion stop ring (2).

Fig 3: Identifying Over-Running Clutch Assembly, Gear Shaft, Pinion Stop Ring & Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Insert shaft assembly (1) into front housing with lever (2) positioned as shown in the figure.

Fig 4: Identifying Shaft Assembly & Lever
Courtesy of SUZUKI OF AMERICA CORP.
Install packing (1) so that cuts in packing align with holes for through bolts in front housing.
Install plate and seal rubber (4) to front housing.

Fig 5: Identifying Plate And Seal Rubber, Packing, Planetary Gear & Bolt Hole
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to ball (1) and install ball (1) into shaft hole.

Fig 6: Identifying Ball
Courtesy of SUZUKI OF AMERICA CORP.
Install yoke, armature, brush holder and rear bracket to front housing (2) by aligning match marks provided before removal.
Tighten through bolts (1).

Fig 7: Identifying Bolts & Front Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install magnetic switch assembly (1) and protector (2) (if equipped). Connect wire (switch to motor) to switch terminal.

Fig 8: Identifying Protector And Magnetic Switch Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Upon completion of assembly, carry out performance test. Refer to STARTING MOTOR PERFORMANCE TEST .