Starting Motor Reassembly

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING 

Reference: STARTING MOTOR DISASSEMBLY 

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: Identifying Brushes, Brush Springs & Brush Holder

   Courtesy 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: Identifying Rear Bracket & Brush Holder Screws

   Courtesy 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: Identifying Over-Running Clutch Assembly, Gear Shaft, Pinion Stop Ring & Snap Ring

   Courtesy of SUZUKI OF AMERICA CORP.
10. 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.
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: Identifying Plate And Seal Rubber, Packing, Planetary Gear & Bolt Hole

    Courtesy of SUZUKI OF AMERICA CORP.
13. Apply grease to ball (1) and install ball (1) into shaft hole.
    Fig 6: Identifying Ball

    Courtesy 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: Identifying Bolts & Front Housing

    Courtesy 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: Identifying Protector And Magnetic Switch Assembly

    Courtesy of SUZUKI OF AMERICA CORP.
17. Upon completion of assembly, carry out performance test. Refer to STARTING MOTOR PERFORMANCE TEST .