Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 200
1I-8 Starting System: For Petrol Engine Model
Brush Spring
Inspect brush springs for wear, damage or other
abnormal conditions. Replace if necessary.
Brush spring tension
Standard: 1.8 kg (3.97 lb)
Limit: 0.3 kg (0.67 lb)
Brush Holder
• Check movement of brush in brush holder. If brush
movement within brush holder is sluggish, check
brush holder for distortion and sliding faces for
contamination. Clean or correct as necessary.
• Check for continuity across insulated brush (positive
side) and grounded brush (negative side). If continuity
exists, brush holder is grounded due to defective
insulation and should be replaced.
Armature
• Inspect commutator for dirt or burn. Correct with
sandpaper or lathe, if necessary.
• Check commutator for uneven wear with armature (1)
supported on V-blocks (2). If deflection of dial gauge
(4) pointer exceeds limit, repair or replace.
NOTE
The following specification presupposes that
armature is free from bend. Bent armature
must be replaced.
Commutator out of round
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.4 mm (0.016 in.)
• Inspect commutator for wear. If diameter is below
limit, replace armature.
Commutator outside diameter
Standard: 29.4 mm (1.16 in.)
Limit: 28.8 mm (1.13 in.)
I4RS0A190004-01
IYSQ01190034-01
3. Magnetic stand
IYSQ01190035-01
IYSQ01190036-01
Starting System: For Petrol Engine Model 1I-9
• Inspect commutator for insulator depth. Correct or
replace if below limit.
Commutator insulator depth “a”
Standard: 0.4 – 0.6 mm (0.016 – 0.024 in.)
Limit: 0.2 mm (0.008 in.)
Ground test
Check the commutator and armature core. If there is
continuity, armature is grounded and must be replaced.
Open circuit test
Check for continuity between segments. If there is no
continuity at any test point, there is an open circuit and
the armature must be replaced.
Gears
Inspect internal gear and the planetary gears for wear,
damage or other abnormal conditions. Replace if
necessary.
Pinion and Over-Running Clutch
• Inspect pinion for wear, damage or other abnormal
conditions. Check that clutch locks up when turned in
direction of drive and rotates smoothly in reverse
direction. Replace if necessary.
• Inspect spline teeth for wear or damage. Replace if
necessary. Inspect pinion for smooth movement.
Front Housing Bush
Inspect bush for wear or damage. Replace if necessary.
[A]: Correct
1. Commutator segment
[B]: Incorrect
2. Insulator
I5JB0A190003-01
IYSQ01190038-01
IYSQ01190039-01
IYSQ01190040-01
IYSQ01190041-01
IYSQ01190042-01
IYSQ01190043-01
1I-10 Starting System: For Petrol Engine Model
Specifications
Starting Motor Specifications
S6JB0A1917001
1.2 kW Type [1.4 kW Type]
Tightening Torque Specifications
S6JB0A1917002
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting: For Petrol Engine Model”
“Starting Motor Components: For Petrol Engine Model”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
Special Tools and Equipment
Recommended Service Material
S6JB0A1918001
NOTE
Required service material is also described in the following.
“Starting Motor Components: For Petrol Engine Model”
Voltage
12 volts
Output
1.2 kW [1.4 kW]
Rating
30 seconds
Direction of rotation
Clockwise as viewed from pinion side
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 5.5 mm (0.22 in.)
Number of pinion teeth
8
Performance
Condition
Guarantee
Around
at 20
°C (68 °F)
No load characteristic
11.0 V
90 A maximum
2370 r/min minimum [2000 r/min minimum]
Load characteristic
7.5 V
300 A
10.65 N
⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
[11.0 N
⋅m (1.1 kgf-m, 7.95 lb-ft) minimum]
840 r/min minimum
Locked characteristic
4.0 V
[3.0 V]
780 A maximum
[860 A maximum]
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Starting motor battery cable nut
11
1.1
8.0
Starting System: For Diesel Engine Model 1I-11
For Diesel Engine Model
General Description
Cranking Circuit Introduction
S6JB0A1921001
The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These
components are connected electrically.
Starting Motor Circuit Description
S6JB0A1921002
• The magnetic switch coils are magnetized when the ignition switch is closed.
• The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and
the magnetic switch main contacts to close, and cranking takes place.
• When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch
is opened, at which time the return spring causes the pinion to disengage.
I5JB0B190001-01
1. Pinion drive lever
5. Magnetic switch contacts
9. Starting motor
2. Plunger
6. Pinion and over-running clutch
10. Battery
3. Hold-in coil
7. Pull-in coil
11. Ignition and starting motor switch
4. Magnetic switch
8. Return spring
12. Starting motor control relay
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