Starting Motor Disassembly And Assembly: Assembly

Reference: STARTING MOTOR COMPONENTS 

1. Inspect component parts referring to STARTING MOTOR INSPECTION  and replace with new ones as necessary.
2. Apply grease referring to STARTING MOTOR COMPONENTS .
3. Install armature to yoke.
4. Install brushes (1) and brush springs (2) to brush holder (3).
   Fig 1: Identifying Brushes, Brush Springs & Brush Holder

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install brush holder to armature while pushing 4 brushes outward.
6. Install rear bracket (1).
7. Tighten brush holder screws (2).
   Fig 2: Identifying Rear Bracket & Brush Holder Screws

   Courtesy of SUZUKI OF AMERICA CORP.
8. Install internal gear and 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

   Courtesy of SUZUKI OF AMERICA CORP.
9. 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.
10. Install packing (1) so that cuts in packing align with holes for through bolts in front housing.
11. Install plate and seal rubber (4) to front housing.
    Fig 5: Identifying Packing, Seal Rubber & Planetary Gear

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

    Courtesy of SUZUKI OF AMERICA CORP.
14. Install magnetic switch (1), spring (2) and plunger (3) to front housing (5) by aligning match marks provided before removal and then tighten screws (4).
    Fig 7: Identifying Magnetic Switch, Spring & Plunger

    Courtesy of SUZUKI OF AMERICA CORP.
15. Install protector (2) and tighten screws (1).
    Fig 8: Identifying Protector

    Courtesy of SUZUKI OF AMERICA CORP.
16. Connect lead wire (1) to terminal "M" (2).
    Fig 9: Identifying Lead Wire & Terminal M

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