Mark mating surfaces of starter housing and solenoid housing and starter housing and yoke for reassembly reference. Remove starter housing field coil lead from solenoid terminal. Remove 2 screws holding solenoid to starter housing. Remove solenoid.
NOTE: On conventional type starter, remove solenoid from starter housing by lifting up and out to release hook from pinion lever.
Loosen and remove 2 bolts and 2 screws holding commutator cover to starter housing. On conventional type starter, remove armature plate and brake spring. Remove commutator cover from yoke. Separate brush holder, armature and yoke from starter housing.
On reduction type starter, remove gasket and gears. Remove seal rubber and plate. Remove shaft assembly and lever. On all models, draw brushes from brush holder.
To remove overrunning clutch, pull pinion stop ring in toward clutch side. Remove snap ring using Snap Ring Pliers (09900-06107). Remove pinion stop ring, and slide off overrunning clutch. See Fig 1. On reduction type starter, remove circlip and pull planetary carrier shaft from center bearing and shock absorber assembly.

Fig 1: Locating Snap Ring under Pinion Stop Ring

Courtesy of SUZUKI OF AMERICA CORP.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Repair and Diagnosis: Electrical: Starter: Overhaul: Disassembly