Tracker 2000-2004

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter motor wiring connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 22 ft. lbs. (30 Nm).
     
    Starter motor wiring connectors. Tighten the solenoid nut to 11 ft. lbs. (15 Nm).
     
    Negative battery cable
     

  2.  

Solenoid or Relay




NOTE
Prior to removing the solenoid from the starter motor unit, matchmark the solenoid-to-starter motor housing position, as shown in the accompanying illustration.

  1. Remove the starter motor from the vehicle.
  2.  
  3. Detach the solenoid-to-starter motor wire from the solenoid terminal.
    NOTE
    Do not disassemble the solenoid; if the solenoid is defective, replace the entire unit with a new one.

  4.  
  5. Remove the two attaching screws, then slide the solenoid out of the starter motor housing flange.

    Click image to see an enlarged view

    Fig. Before removing the starter motor solenoid, matchmark the solenoid-to-starter motor housing relationship



    Click image to see an enlarged view

    Fig. Disconnect the field coil lead from the solenoid by loosening the retaining nut . . .



    Click image to see an enlarged view

    Fig. . . . then remove the two attaching screws and separate the solenoid from the motor housing

  6.  

To install:

  1. Inspect the solenoid plunger joint for wear or other damage. Replace it, if damage is evident.
  2.  
  3. Apply Suzuki Super Grease A (99000-25010) or equivalent, to the solenoid plunger and to the tip of the lever arm (inside the starter motor-to-solenoid housing hole).
  4.  
  5. Insert the solenoid into the starter motor housing, ensuring that the matchmarks made during removal are aligned.
  6.  
  7. Install and tighten the two attaching screws securely.
  8.  
  9. Attach the starter motor-to-solenoid wire to the solenoid terminal.
  10.  
  11. While the starter motor is removed form the vehicle, perform the testing procedure to ensure that the new solenoid functions properly.
  12.  
  13. Install the starter motor.
  14.  

 
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