Suzuki Grand Vitara JB416 / JB420. Manual — part 134
1I-4 Starting System:
Starting Motor Performance Test
S5JB0A1904002
CAUTION
!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.
Pull-In Test
1) Connect battery to magnetic switch as shown.
2) Check that plunger and pinion move outward. If
plunger and pinion don’t move, replace magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M”.
Hold-In Test
1) While connected as above with plunger out,
disconnect negative lead (2) from terminal “M” (1).
2) Check that plunger and pinion remain out. If plunger
and pinion return inward, replace magnetic switch.
Plunger and Pinion Return Test
1) Disconnect negative lead (1) from switch body (2).
2) Check that plunger and pinion return inward. If
plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
1) Connect battery and ammeter to starter as shown.
2) Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (no-load performance test)
90 A MAX. at 11 V
NOTE
Use wires as thick as possible and tighten
each terminal fully.
1. Terminal “S”
2. Terminal “M”
3. Lead wire (switch to motor)
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Starting System: 1I-5
Repair Instructions
Starting Motor Dismounting and Remounting
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Dismounting
1) Disconnect negative (–) battery lead at battery.
2) Hoist vehicle
3) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
4) Remove starting motor mount bolts (3).
5) Remove starting motor (4).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (5) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
(a)
(c)
(a)
(b)
(b)
[A]
[B]
3
3
4
5
4
5
2
1
3
1
2
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[A]: For M16 Engine
: 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
: 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
[B]: For J20 Engine
: 25 N
⋅m (2.5 kgf-m, 18.5 lb-ft)
1I-6 Starting System:
Starting Motor Components
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The starting motor consists of parts shown in below and has permanent magnets mounted in starting motor yoke
(frame).
The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be
protected against possible dirt and water splash.
NOTE
Spare parts have been lubricated.
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1. Front housing
7. Plate
13. Planetary gear
19. Rear bush
2. Bush
8. Seal rubber
14. Packing
: 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Pinion stop ring
9. Magnetic switch
15. Yoke
: Do not reuse.
4. Over-running clutch
10. Starting motor battery cable nut
16. Armature
: Apply grease 99000-25010 to sliding surface of each part.
5. Lever
11. Internal gear
17. Brush assembly
6. Plunger
12. Planetary carrier shaft
18. Rear bracket
Starting System: 1I-7
Starting Motor Inspection
S5JB0A1906004
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-In coil open circuit test
Check for continuity across magnetic switch “S” terminal
and “M” terminal. If no continuity exists, coil is open and
should be replaced.
Hold-In coil open circuit test
Check for continuity across magnetic switch “S” terminal
and coil case. If no continuity exists, coil is open and
should be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear.
Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 5.5 mm (0.22 in.)
• Install brushes to each brush holder and check for
smooth movement.
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