Starting System Suzuki Grand Vitara II

CRANKING CIRCUIT INTRODUCTION

The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically.

Scheme 1

1. The magnetic switch coils are magnetized when the ignition switch is closed.
2. 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.
3. 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.

CRANKING SYSTEM SYMPTOM DIAGNOSIS

Possible symptoms due to starting system trouble would be as follows

1. Starting motor does not run (or runs slowly)
2. Starting motor runs but fails to crank engine
3. Abnormal noise is heard

Proper diagnosis must be made to determine exactly where the cause of each trouble lies, i.e. in battery, wiring harness, (including starting motor switch), starting motor or engine.

Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of possible causes.

1. Condition of trouble
2. Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3. Discharge of battery
4. Mounting of starting motor

CRANKING SYSTEM DIAGNOSTIC PROCEDURE CHART

STARTING MOTOR PERFORMANCE TEST

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING

Scheme 2

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".

Scheme 3

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.

Scheme 4

1. Disconnect negative lead (1) from switch body (2).
2. Check that plunger and pinion return inward. If plunger and pinion don't return, disassemble and inspect starting motor.

Scheme 5

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.

Scheme 6

Dismounting

1. Disconnect negative (-) cable at battery.
2. Dismounting generator referring to «GENERATOR DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2005-2008/remont/charging-system/#charging-system) .
3. Disconnect magnetic switch lead wire and battery cable from starting motor terminals.
4. Remove 2 starting motor mount bolts.
5. Remove starting motor.

Remounting

Reverse the dismounting procedure noting the following.

1. Tighten starting motor mount bolt (1) and starting motor battery cable nut.

Tightening torque

Starting motor mount bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Starting motor battery cable nut: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Scheme 7

STARTING MOTOR DISASSEMBLY AND ASSEMBLY

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING

Disassembly

Note. Do not clamp yoke in a vise or strike it with a hammer during repair operations.

Scheme 8

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Scheme 21

1. Disconnect lead wire (1) from terminal "M" (2).
2. Loosen screws (1) and then remove protector (2).
3. Put match marks at 2 locations (A (magnetic switch (1) and front housing (2)) and B (front housing (2) and yoke (3))) as shown in figure so that any possible mistake can be avoided.
4. Loosen screws (4) and then remove magnetic switch (1), spring (2) and plunger (3). CAUTION: Don't disassemble magnetic switch. If defective, replace as a complete assembly.
5. Remove through bolts (1) shown in the figure, then separate reduction gear assembly (2) from starting motor assembly.
6. To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).
7. Remove seal rubber (1) and plate (2).
8. Remove shaft assembly (1) with lever (2).
9. Loosen pinion stop ring (2) fixed by snap ring (1).
10. Remove snap ring (2), then pull out pinion stop ring (3) and over-running clutch (4) and internal gear (1). Special Tool 09900-06107
11. Remove rear bracket (1) and brush holder.
12. Remove armature (1) from yoke (2).
13. Remove brush holder (2) from rear bracket (1).
14. Remove brush springs (1) and brushes (2).

Assembly

Reference: STARTING MOTOR COMPONENTS

Scheme 22

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Scheme 30

1. Inspect component parts referring to «STARTING MOTOR INSPECTION»(/suzuki/grand-vitara/ii-2005-2008/remont/starter/#starting-system__starting-motor-inspection) and replace with new ones as necessary.
2. Apply grease referring to «STARTING MOTOR COMPONENTS»(/suzuki/grand-vitara/ii-2005-2008/remont/starter/#starting-system) .
3. Install armature to yoke.
4. Install brushes (1) and brush springs (2) to brush holder (3).
5. Install brush holder to armature while pushing 4 brushes outward.
6. Install rear bracket (1).
7. Tighten brush holder screws (2).
8. Install internal gear and over-running clutch assembly (1) to gear shaft (4), using care for installing direction of pinion stop ring (2).
9. Insert shaft assembly (1) into front housing with lever (2) positioned as shown in the figure.
10. Install packing (1) so that cuts in packing align with holes for through bolts in front housing.
11. Install plate and seal rubber (4) to front housing.
12. Install yoke, armature, brush holder and rear bracket to front housing (2) by aligning match marks provided before removal.
13. Tighten through bolts (1).
14. Install magnetic switch (1), spring (2) and plunger (3) to front housing (5) by aligning match marks provided before removal and then tighten screws (4).
15. Install protector (2) and tighten screws (1).
16. Connect lead wire (1) to terminal "M" (2).
17. Upon completion of assembly, carry out performance test. Refer to «STARTING MOTOR PERFORMANCE TEST»(/suzuki/grand-vitara/ii-2005-2008/remont/starter/#starting-system__starting-motor-performance-test) .

STARTING MOTOR INSPECTION

Reference: STARTING MOTOR DISMOUNTING AND REMOUNTING

Reference: STARTING MOTOR DISASSEMBLY AND ASSEMBLY

Plunger

Inspect plunger for wear. Replace if necessary.

Scheme 31

Magnetic Switch

Push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary.

Scheme 32

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.

Scheme 33

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.

Scheme 34

Armature Shaft Bush

Inspect bush for wear or damage. Replace if necessary.

Scheme 35

Scheme 36

1. Check brushes for wear. Measure length of brushes and if below limit, replace brush. Brush length Standard: 12.3 mm (0.48 in.) Limit: 5.5 mm (0.22 in.)
2. Install brushes to each brush holder and check for smooth movement.

Brush Spring

Inspect brush springs for wear, damage or other abnormal conditions. Replace if necessary.

Scheme 37

1. 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.
2. Check for continuity across brush positive terminal (1) and grounded brush holder (2). If continuity exists, brush holder is grounded due to defective insulation and should be replaced.

Scheme 38

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Scheme 41

1. Inspect commutator for dirt or burn. Correct with sandpaper or lathe, if necessary.
2. Check commutator for uneven wear with armature (1) supported on V-blocks (2). If deflection of dial gauge pointer exceeds limit, repair or replace. NOTE: Below 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.)
3. 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.)
4. Inspect commutator for insulator depth. Correct or replace if below limit. Commutator insulator depth "a" Standard: 0.5 mm (0.020 in.) Limit: 0.2 mm (0.008 in.)

Ground test

Check commutator and armature core. If there is continuity, armature is grounded and must be replaced.

Scheme 42

Open circuit test

Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced.

Scheme 43

Gears

Inspect internal gear and planetary gears for wear, damage or other abnormal conditions. Replace if necessary.

Scheme 44

Scheme 45

Scheme 46

1. 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.
2. 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.

Scheme 47

1.4 kW Type

STARTING MOTOR SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS

Note. Specified tightening torque is also found in (Scheme 6).

RECOMMENDED SERVICE MATERIAL

Note. Required service material is also found in (Scheme 6).

SPECIAL TOOL

SPECIAL TOOLS DESCRIPTION 09900-06107 Snap ring pliers (opening type)

Scheme 48

See also:
• GENERATOR DISMOUNTING AND REMOUNTING
• STARTING MOTOR DISMOUNTING AND REMOUNTING
• STARTING MOTOR INSPECTION
• STARTING MOTOR PERFORMANCE TEST
• STARTING MOTOR DISASSEMBLY AND ASSEMBLY