Join Date: Nov 2015
Location: Ontario, Canada
When installing the starter assembly, I noticed the OEM bolts have a large flange made in as a part of the bolt head. The recoil housing is made just large enough that these stock supplied bolts will impact the corner where the metal around the bolt hole folds into the starter body. To get around this I took a trip to Home Depot and picked up 4 M6 bolts and matching washers. The properly matched M6 washers are quite a bit smaller on the O.D. than the O.D. of the flange on the bolts. In the photo, you can see how the flange impacts the starter housing. I thought I could get away with maybe just needing one or two new bolts but in the end it was far better to just go with all 4. I am a big advocate for keeping things stock when it comes to fasteners because the OEMs usually use some very high quality items. As an example, my Yamaha SuperJet uses heavily chrome plated bolts. I have priced these things both through external sources and directly from Yamaha...they are super expensive no matter how you find them. In this case, because I did not want to damage the starter housing by any amount, I used the smaller M6 washers. Also, when installing this starter I found it to be very beneficial to take the time and be sure to get all the bolts hand threaded in about 5 or 6 threads first before using the 1/4 inch drive ratchet. The holes on the starter body are just barely larger than the O.D. of the M6 bolts. I had to move the body around a tiny bit to give relief to each bolt so it would thread in easily.
As an additional note, the stock supplied bolts have a threaded portion of 13.5mm long. The M6 bolts I bought from Home Depot only came in 16mm thread length. By the time I added the washer, the threaded length ended up at 14.5mm. When I measured the threads in the holes, the best I could estimate is that Suzuki threaded the holes down to 16mm deep. Beyond that there is not more thread but the holes to carry on until about 21mm overall depth.
Last edited by Bigfoot; 05-10-2019 at 08:56 PM.