Suzuki Burgman 400 - Service manual > Schematic and Routing Diagram

Starting System Diagram

Component Location

Starting System Components Location

Refer to "Electrical Components Location".

Diagnostic Information and Procedures

Starter Motor will not Run

NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing.

Troubleshooting

Engine does not turn though the starter motor runs.

• Faulty starter clutch.

Repair Instructions

Starter Motor Components

1. Housing end (Outside)
2. O-ring
3. Starter motor case
4. Armature
5. Housing end (Inside)
6. O-ring
7. Oil seal
8. Washer
9. Shim
10. Starter motor housing bolt
11. Starter motor lead wire bolt
12. Starter motor mounting bolt

1. 4 N*m (0.4 kgf-m, 3.0 lb-ft)
2. 3 N*m (0.3 kgf-m, 2.0 lb-ft)
3. 7 N*m (0.7 kgf-m, 5.0 lb-ft)

Apply grease to sliding surface.

Apply moly paste to sliding surface.

Apply thread lock to thread part.

Do not reuse.

Starter Motor Removal and Installation

Removal

1) Remove the air cleaner box. Refer to "Air Cleaner Box Removal and Installation ".

2) Remove the starter motor (1).

Installation

Install the starter motor in the reverse order of removal.

Pay attention to the following points.

• Apply grease to the O-ring.

: Grease 99000-25010 (SUZUKI SUPER GREASE A or equivalent)

• Tighten the bolts to the specified torque.

Tightening torque
Starter motor mounting bolt (a): 7 N*m (0.7 kgf-m, 5.0 lb-ft)
Starter motor lead wire bolt (b): 3 N*m (0.3 kgf-m, 2.0 lb-ft)

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