Starting Motor Disassembly

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING

NOTE:

Before disassembling starting motor, be sure to put match marks at 2 locations (A (magnetic clutch (1) and front housing (2)) and B (front housing (2) and yoke (3))) as shown in figure so that any possible mistake can be avoided.
Do not clamp yoke in a vise or strike it with a hammer during repair operations.

Fig 1: Identifying Magnetic Clutch, Front Housing & Yoke
Courtesy of SUZUKI OF AMERICA CORP.

Remove protector (2) (if equipped) and magnetic switch (1).

Fig 2: Identifying Protector And Magnetic Switch
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Don't disassemble this switch. If defective, replace as a complete assembly.

Fig 3: Identifying Magnetic Switch, Spring And Plunger
Courtesy of SUZUKI OF AMERICA CORP.
Remove bolts (1) shown in the figure, then separate reduction gear assembly (2) from starting motor assembly.

Fig 4: Identifying Bolts & Reduction Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).

Fig 5: Identifying Packing And Planetary Gears
Courtesy of SUZUKI OF AMERICA CORP.
Remove seal rubber (1) and plate (2).

Fig 6: Identifying Seal Rubber And Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove shaft assembly (1) with lever (2).

Fig 7: Identifying Shaft Assembly & Lever
Courtesy of SUZUKI OF AMERICA CORP.
Loosen pinion stop ring (2) fixed by snap ring (1).

Fig 8: Identifying Pinion Stop Ring, Snap Ring & Over-Running Clutch Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (2), then pull out pinion stop ring (3) and over-running clutch (4) and internal gear (1).
Special Tool

(A): 09900-06107

Fig 9: Identifying Snap Ring, Over-Running Clutch, Pull Out Pinion Stop Ring & Internal Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear bracket (1) and brush holder.

Fig 10: Identifying Rear Bracket, Armature & Yoke
Courtesy of SUZUKI OF AMERICA CORP.
Remove armature (1) from yoke (2) and then ball (3) from the end of armature shaft.

Fig 11: Identifying Armature, Yoke & Ball
Courtesy of SUZUKI OF AMERICA CORP.
Remove brush holder (2) from rear bracket (1).

Fig 12: Identifying Brush Holder & Rear Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Remove brush springs (1) and brushes (2).

Fig 13: Identifying Brush Springs And Brushes
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear bracket cap (2) from rear bracket (3), and then remove rear bush (1) from rear bracket (3), as required.

Fig 14: Identifying Rear Bracket Cap, Rear Bracket & Rear Bush
Courtesy of SUZUKI OF AMERICA CORP.