Starting Motor Disassembly And Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not clamp yoke in a vise or strike it with a hammer during repair operations.

Disconnect lead wire (1) from terminal "M" (2).

Fig 1: Identifying Lead Wire & Terminal M
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Loosen screws (1) and then remove protector (2).

Fig 2: Identifying Protector
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Put match marks at 2 locations (A (magnetic switch (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.

Fig 3: Identifying Magnetic Switch, Front Housing & Yoke
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Loosen screws (4) and then remove magnetic switch (1), spring (2) and plunger (3).
CAUTION: Don't disassemble magnetic switch. If defective, replace as a complete assembly.

Fig 4: Identifying Magnetic Switch, Spring & Plunger
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Remove through bolts (1) shown in the figure, then separate reduction gear assembly (2) from starting motor assembly.

Fig 5: Identifying Reduction Gear Assembly
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To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).

Fig 6: Identifying Packing & Planetary Gears
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Remove seal rubber (1) and plate (2).

Fig 7: Identifying Seal Rubber & Plate
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Remove shaft assembly (1) with lever (2).

Fig 8: Identifying Shaft Assembly & Lever
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Loosen pinion stop ring (2) fixed by snap ring (1).

Fig 9: Locating Pinion Stop Ring
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Remove snap ring (2), then pull out pinion stop ring (3) and over-running clutch (4) and internal gear (1).
Special Tool
1. 09900-06107
Fig 10: Identifying Snap Ring, Pinion Stop Ring, Over-Running Clutch & Internal Gear
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Remove rear bracket (1) and brush holder.

Fig 11: Identifying Rear Bracket, Armature & Yoke
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Remove armature (1) from yoke (2).

Fig 12: Identifying Armature & Yoke
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Remove brush holder (2) from rear bracket (1).

Fig 13: Identifying Brush Holder & Rear Bracket
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Remove brush springs (1) and brushes (2).

Fig 14: Identifying Brush Springs & Brushes
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