Starting Motor Disassembly and Reassembly: Reassembly

Reference: STARTING MOTOR INSPECTION 

1. Install brush springs (2) and brushes (1) to brush holder (3).
   Fig 1: Identifying Brush Springs, Brushes And Brush Holder

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2. Install armature (2) to yoke.
3. Install brush assembly (1) to armature (2) while pushing 4 brushes (3) outward.
   Fig 2: Install Brush Assembly To Armature

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4. Install end housing (1) to brush holder and tighten brush holder screws (2) to specified torque.

   Tightening torque 

   Brush holder screw (a): 3.5 N.m (0.36 kg-m, 3.0 lbf-ft) 

   Fig 3: Identifying Brush Holder Screws And End Housing

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5. Before installing overrunning clutch (2) and internal gear (3) to gear shaft (1), apply grease to shaft spline.

   "A": Grease 99000-25011 (SUZUKI Super Grease A) 

   Fig 4: Identifying Overrunning Clutch, Internal Gear And Gear Shaft

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6. Install internal gear and overrunning clutch (1) to gear shaft (4) with new snap ring (3) and pinion stop ring (2).
   NOTE: Install pinion stop ring in the direction and position as shown in figure.
   Fig 5: Identifying Overrunning Clutch, Gear Shaft, Snap Ring And Pinion Stop Ring

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7. Apply grease to drive lever (2) and insert shaft assembly (1) into armature housing with drive lever positioned as shown in the figure.

   "A": Grease 99000-25011 (SUZUKI Super Grease A) 

   Fig 6: Inserting Shaft Assembly To Armature Housing With Drive Lever

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8. With armature housing bolt holes (3) and grommet cutting positions aligned, install grommet (1) in armature housing.
9. Install plate (5) and seal rubber (4) to armature housing.
10. Apply grease to planetary gears (2) and Install planetary gears to gear shaft.

    "A": Grease 99000-25011 (SUZUKI Super Grease A) 

    Fig 7: Identifying Armature Housing Bolt Holes, Seal Rubber And Plate

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11. Install yoke, armature, brush assembly and end housing (4) to armature housing (2) in alignment with matchmark (3) drawn before disassembly.
12. Tighten end housing bolts (1) to specified torque.

    Tightening torque 

    End housing bolt (a): 6.0 N.m (0.61 kg-m, 4.5 lbf-ft) 

    Fig 8: Identifying End Housing Bolts, Armature Housing With Matchmark

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13. Apply grease to plunger.

    "A": Grease 99000-25011 (SUZUKI Super Grease A) 

    Fig 9: Identifying Plunger Grease Applying Area

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14. Install magnetic switch (1), spring (2) and plunger (3) to armature housing (5) in alignment with matchmark drawn before removal.
15. Tighten screws (4) to specified torque.

    Tightening torque 

    Magnetic switch screw (a): 6.0 N.m (0.61 kg-m, 4.5 lbf-ft) 

    Fig 10: Identifying Magnetic Switch, Spring, Plunger, Armature Housing And Screws

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16. Connect lead wire (1) to terminal "M" (2) and tighten lead wire nut to specified torque.

    Tightening torque 

    Lead wire nut (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft) 

    Fig 11: Identifying Lead Wire Nut And Terminal "M"

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17. Check magnetic switch for operation, see STARTING MOTOR INSPECTION .