Starters Suzuki Grand Vitara I

DESCRIPTION & OPERATION

Two types of starters are used. A direct drive starter or a gear reduction starter may be used depending on vehicle application. Both types of starters consist of front housing, overrunning clutch assembly, armature, yoke, starter solenoid, brush holder, rear housing and drive lever. Gear reduction starter also contains a gear reduction assembly.

When ignition is in START position, starter solenoid is activated and energizes the starter. When starter is energized, overrunning clutch assembly and drive pinion move outward, and drive pinion engages with the flywheel gear. When engine starts, overrunning clutch assembly protects armature from excessive speed until ignition is moved from START position. Return spring disengages drive pinion from flywheel gear.

CLUTCH PEDAL SWITCH (M/T)

1. Apply parking brake. Place shift lever in Neutral. Disconnect electrical connector from clutch pedal switch, located near top of clutch pedal. (Scheme 1)
2. Loosen lock nut on clutch pedal switch. Unscrew clutch pedal switch from mounting bracket. Connect ohmmeter between electrical terminals on clutch pedal switch for checking switch continuity.
3. Fully depress clutch pedal. Slowly release clutch pedal until the distance from top of pedal pad on clutch pedal to the floor is 1.0" (25 mm). Hold clutch pedal in this position.
4. Slowly screw clutch pedal switch into mounting bracket until continuity exists between electrical terminals on clutch pedal switch. Hold clutch pedal switch and tighten lock nut to specification. See «TORQUE SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__torque-specifications).
5. Fully depress clutch pedal. Ensure plunger distance between tip of plunger on clutch pedal switch and end of clutch pedal switch is within specification. See «PLUNGER DISTANCE SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters) table. (Scheme 1)
6. Readjust clutch pedal switch if proper plunger distance does not exist. Remove ohmmeter. Install harness connector.

PLUNGER DISTANCE SPECIFICATIONS

Scheme 1

TRANSMISSION RANGE SWITCH (A/T)

Note. Transmission range switch may also be referred to as Park/neutral position switch or shift switch.

Esteem, Grand Vitara & Vitara

Apply parking brake. Place shift lever in Neutral. Loosen transmission range switch retaining bolts. Rotate transmission range switch so neutral reference line aligns with center line on manual valve shaft. (Scheme 2)or (Scheme 3). Tighten transmission range switch retaining bolts.

Swift

1. Transmission range switch is located on side of transaxle. Loosen transmission range switch retaining bolt.
2. Rotate transmission range switch in direction of arrow until a click is heard or felt. (Scheme 4) Tighten transmission range switch retaining bolt.

Scheme 2

Scheme 3

Scheme 4

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

Clutch pedal switch is located at top of clutch pedal. Continuity should exist between electrical terminals on clutch pedal switch when clutch pedal switch is fully depressed and continuity should not exist when clutch pedal is released. Testing information is not available.

IGNITION SWITCH

For ignition switch testing, see appropriate STEERING COLUMN SWITCHES article.

Note. Transmission range switch may also be referred to as park/neutral position switch or shift switch.

Grand Vitara & Vitara

1. Apply parking brake. Disconnect harness connector at transmission range switch, located on side of transmission.
2. Using ohmmeter, check for continuity between specified terminals at transmission range switch with shift lever in specified positions. See «TRANSMISSION RANGE SWITCH SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters) table. (Scheme 5)or (Scheme 6). If continuity is not as specified, adjust or replace switch as necessary.

TRANSMISSION RANGE SWITCH SPECIFICATIONS

Scheme 5

Scheme 6

STARTER NO-LOAD TEST

1. Connect ammeter, battery voltage and ground to starter. (Scheme 7) Ensure starter rotates smoothly, drive pinion moves outward and no-load current draw is within specification. See «STARTER SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__starter-specifications).
2. Disconnect test equipment. Repair starter if starter no-load current draw is not within specification or drive pinion does not move outward. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__overhaul).

Scheme 7

STARTER SOLENOID

Note. Perform starter solenoid tests with field coil lead wire disconnected from starter solenoid.

Pull-In Test

Ensure field coil lead wire is disconnected from starter solenoid. Connect battery voltage and ground to starter. (Scheme 8) Replace starter solenoid if drive pinion does not move outward. Disconnect test equipment.

Scheme 8

Hold-In & Return Test

1. Ensure field coil lead wire is disconnected from starter solenoid. Connect battery voltage and ground to starter, as when performing starter solenoid pull-in test. (Scheme 8)
2. Once drive pinion moves outward, disconnect jumper wire from terminal "M" on the starter solenoid. (Scheme 8) Drive pinion should remain outward. Replace starter solenoid if drive pinion does not remain outward.
3. Disconnect jumper wire from negative battery terminal at the starter. Drive pinion should move inward. If drive pinion does not move inward, disassemble starter and inspect. Repair as necessary. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__overhaul).

BRUSHES & BRUSH HOLDER

1. Ensure brushes slide freely in brush holder. If brushes do not slide freely, check for dirt or contamination. Clean brushes and recheck operation. Replace brushes if brushes still do not slide freely.
2. To check brush holder for a ground, use ohmmeter and check for continuity between insulated brush holder and grounded brush holder. (Scheme 9)or (Scheme 10). No continuity should exist. Replace brush holder if continuity exists.
3. Inspect brushes for cracks. Using caliper, measure brush length. Replace brush if brush length is not within specification. See «STARTER SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__starter-specifications).

Scheme 9

Scheme 10

ARMATURE

1. Inspect commutator for dirt or burn spots. Correct with sandpaper or lathe as necessary.
2. To check armature for a grounded circuit, use ohmmeter to check for continuity between commutator and armature coil core. (Scheme 11) No continuity should exist. Replace armature if continuity exists.
3. To check for an open circuit, use ohmmeter to check for continuity between individual brush segment at commutator end of armature. (Scheme 11) Continuity should exist between each individual brush segment. Replace armature if no continuity exists on any brush segment.
4. Support armature in "V" blocks, with "V" block positioned at each bearing end of armature. Using dial indicator, check armature runout center of commutator at end of armature. Replace armature if armature runout exceeds.015" (.40 mm).
5. Using caliper, measure commutator outside diameter at center of commutator. Replace armature if commutator outside diameter is not within specification. See «STARTER SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__starter-specifications).
6. Measure insulator depth at grooves between commutator segments. (Scheme 12) Replace armature if insulator depth is not within specification. See «STARTER SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/starter/#starters__starter-specifications).

Scheme 11

Scheme 12

FIELD COIL

Note. Field coil test applies to Swift models equipped with manual transmission only.

Swift (M/T)

Using ohmmeter, check for continuity between field coil lead wire and bare surface on yoke. (Scheme 13) No continuity should exist. Replace yoke if continuity exists.

Scheme 13

OVERHAUL

Note. (Scheme 14), (Scheme 15) or (Scheme 16) for starter overhaul.

Scheme 14

Scheme 15

Scheme 16

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS (ESTEEM)

STARTER SPECIFICATIONS (GRAND VITARA & VITARA)

STARTER SPECIFICATIONS (SWIFT)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starting System Wiring Diagram (Esteem). Scheme 17

Starting System Wiring Diagram (Grand Vitara). Scheme 18

Starting System Wiring Diagram (Swift). Scheme 19

Starting System Wiring Diagram (Vitara). Scheme 20

See also:
• TORQUE SPECIFICATIONS
• PLUNGER DISTANCE SPECIFICATIONS
• STARTER SPECIFICATIONS
• OVERHAUL