Starting Motor Disassembly and Reassembly: Reassembly

Install brush springs (2) and brushes (1) to brush holder (3).

Fig 1: Identifying Brush Springs And Brush Holder
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Install armature to yoke.
Install brush assembly (1) to armature (2) while pushing 4 brushes (3) outward.

Fig 2: Identifying Brush Assembly And Armature
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Install starter end frame (1) to brush holder. 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
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Before installing over-running 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 Over-Running Clutch And Internal Gear
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Install internal gear and over-running clutch (1) to gear shaft (4) with new snap ring (3) noting the direction of pinion stop ring (2).

Fig 5: Identifying Internal Gear And Over-Running Clutch To Gear Shaft
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Apply grease to drive lever (2), insert shaft assembly (1) into starter housing with drive lever positioned as shown in the figure.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Fig 6: Identifying Driver Lever And Insert Shaft Assembly
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Install packing (1) so that cuts in packing align with holes (3) for through bolts in starter housing.
Install plate (5) and seal rubber (4) to starter housing.
Apply grease to planetary gears (2), then Install planetary gears to gear shaft.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Fig 7: Identifying Plate And Seal Rubber In Starter Housing
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Install yoke, armature, brush assembly and starter end frame (4) to starter housing (2) by aligning with alignment mark (3) provided before disassembly.
Tighten starter end frame bolts (1) to specified torque.
Tightening torque

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

Fig 8: Identifying Starter End Frame Bolts
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Apply grease to plunger.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Fig 9: Identifying Plunger
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Install magnetic switch (1), spring (2) and plunger (3) to starter housing (5) by aligning match marks provided before removal, and then 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 And Plunger
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Connect lead wire (1) to terminal "M" (2), and then 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
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After completing assembly, check magnetic switch for operation.