1994 Suzuki SamuraiFACTORY OEM SERVICE PROCEDURE

Repair and Diagnosis: Electrical: Starter: Overhaul: Reassembly

  1. Lubricate all friction surfaces. On reduction type starter, install center bearing and shock absorber assembly onto planetary carrier shaft, and install circlip. See Fig 1 . On all models, install overrunning clutch, pinion stop ring and snap ring (if removed). Install brushes into brush holder.
  2. On reduction type starter, install shaft assembly and lever. Install seal rubber and plate. Install gasket and gears. On all models, install armature, yoke and brush holder into starter housing, matching reference marks scribed during disassembly. Place commutator cover over starter housing.
    Fig 1: Exploded View Of Reduction Starter Motor
    G92D01341Courtesy of SUZUKI OF AMERICA CORP.
  3. On conventional type starter, install armature plate and brake spring. See Fig 2 . On all models, install 2 bolts and 2 screws holding commutator cover to starter housing. Align solenoid with scribe marks and install on starter housing.
    Fig 2: Exploded View Of Conventional Starter Motor
    G92B01340Courtesy of SUZUKI OF AMERICA CORP.
  4. Install and tighten 2 solenoid-to-starter housing screws. Install starter housing field coil lead-to-solenoid terminal and tighten retaining nut.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.