Suzuki Grand Vitara JB627. Manual - part 113

1I-6 Starting System: 

Starting Motor Dismounting and Remounting

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Dismounting

1) Disconnect negative (–) cable at battery.
2) Dismounting generator referring to “Generator 

Dismounting and Remounting in Section 1J”.

3) Disconnect magnetic switch lead wire and battery 

cable from starting motor terminals.

4) Remove 2 starting motor mount bolts.
5) Remove starting motor.

Remounting
Reverse the dismounting procedure noting the following.
• Tighten starting motor mount bolt (1) and starting 

motor battery cable nut.

Tightening torque
Starting motor mount bolt (a):  55 N·m (5.5 kgf-m, 
40.0 lb-ft)
Starting motor battery cable nut:  11 N·m (1.1 kgf-m, 
8.0 lb-ft)

Starting Motor Disassembly and Assembly

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Disassembly

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

 

1)  Disconnect lead wire (1) from terminal “M” (2).

2) Loosen screws (1) and then remove protector (2).

3)  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.

4) 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.

 

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B

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Starting System:  1I-7

5) Remove through bolts (1) shown in the figure, then 

separate reduction gear assembly (2) from starting 
motor assembly.

6) To overhaul reduction gear assembly, remove 

packing (2) and planetary gears (1).

7) Remove seal rubber (1) and plate (2).

8) Remove shaft assembly (1) with lever (2).

9) Loosen pinion stop ring (2) fixed by snap ring (1).

10) Remove snap ring (2), then pull out pinion stop ring 

(3) and over-running clutch (4) and internal gear (1).

Special tool
(A):  09900-06107

11) Remove rear bracket (1) and brush holder.

12) Remove armature (1) from yoke (2).

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3. Over-running clutch assembly

2. Armature
3. Yoke

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1I-8 Starting System: 

13) Remove brush holder (2) from rear bracket (1).

14) Remove brush springs (1) and brushes (2).

Assembly

CAUTION

!

 

New oilless bearing have been lubricated 
when they are supplied as spare parts. 
DO NOT wash with grease dissolving solvent 
nor lubricate them with other lubricant.

 

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).

5) Install brush holder to armature while pushing 4 

brushes outward.

6) Install rear bracket (1).
7) Tighten brush holder screws (2).

8) Install internal gear and over-running clutch 

assembly (1) to gear shaft (4), using care for 
installing direction of pinion stop ring (2).

9) Insert shaft assembly (1) into front housing with lever 

(2) positioned as shown in the figure.

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3. Snap ring

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Starting System:  1I-9

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.

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).

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).

15) Install protector (2) and tighten screws (1).

16) Connect lead wire (1) to terminal “M” (2).

17) Upon completion of assembly, carry out performance 

test. Refer to “Starting Motor Performance Test”.

2. Planetary gear
3. Bolt hole

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