Starters: Overhaul Suzuki Vitara I

Disassembly

Note. Before disassembling starting motor, be sure to put match marks at two locations (A and B), so that any possible mistake can be avoided. Do not clamp yoke (3) in a vise or strike it with a hammer during repair operations. (Scheme 12)

1. Remove protector (2) (if equipped) and magnetic switch (1). (Scheme 14)
2. Remove two bolts (1). Separate reduction gear assembly (2) from starting motor assembly. (Scheme 15)
3. To overhaul reduction gear assembly, remove packing (2) and planetary gear (1). (Scheme 16)
4. Remove seal rubber (1) and plate (2). (Scheme 17)
5. Remove shaft assembly (1) with lever (2). (Scheme 18)
6. Loosen pinion stop ring (2) fixed by snap ring (1). (Scheme 19)
7. Remove snap ring (2), and pull out pinion stop ring (3) and overrunning clutch (4) and internal gear (1). (Scheme 20)
8. Remove rear bracket (1) and brush holder. (Scheme 21)
9. Remove the armature (1) from yoke (2) and ball (3) from the end of the armature shaft. (Scheme 22)
10. Remove brush holder (2) from rear bracket (1). (Scheme 23)
11. Remove brush springs (1) and brushes (2). (Scheme 24)
12. Remove rear bracket cap (2) from rear bracket (3), and remove rear bush (1) from rear bracket (3), as required. (Scheme 25)

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Assembly

1. Inspect component parts. See «BENCH TESTING»(ref-163798-S30146079892004071300000). Replace with new ones as necessary.
2. Apply grease. see scheme 25
3. Install armature to yoke.
4. Install brushes (1) and brush spring (2) to brush holder (3).
5. Install brush holder (3) to armature while pushing 4 brushes (1) outward. (Scheme 26)
6. Install rear bushing and rear bracket cap.
7. Install rear bracket (1).
8. Tighten brush holder screws (2). (Scheme 27)
9. Install overrunning clutch assembly (1) to gear shaft (4), using care for installing direction of pinion stop ring (2). (Scheme 28)
10. Insert shaft assembly (1) into front housing with lever (2) positioned. (Scheme 29)
11. Install packing (1) so that cuts in packing align with holes (3) for through bolt in front housing.
12. Install plate and seal rubber (4) to front housing. Apply grease to ball (5) and install ball into shaft hole.
13. Install yoke, armature, brush holder and rear bracket to front housing (2) by aligning match marks provided before removal. (Scheme 30)
14. Tighten through bolts (1). (Scheme 15)
15. Install magnetic switch assembly (1) and protector (2) (if equipped). Connect wire (switch to motor) to switch terminal. (Scheme 14)
16. Upon completion of assembly, carry out performance test. See «STARTING MOTOR PERFORMANCE TEST»(ref-163798-S42862465412004071300000) under ON-VEHICLE TESTING.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30