Starter: Other Suzuki Sidekick I

Automatic Transmission

Adjust shift lever neutral safety switch by moving switch in direction of arrow. (Scheme 2) Stop and secure switch when click is heard or felt.

Scheme 2

Manual Transmission

Adjust clutch neutral safety switch clearance between switch threaded end and clutch pedal at.04-.06" (1.0-1.5 mm) for Samurai,.12-.16" (3-4 mm) for Sidekick and.02-.04" (0.5-1.0 mm) for Swift. (Scheme 3)

Scheme 3

FIELD COIL

Using a volt/ohmmeter, check for continuity between brush and bare surface. (Scheme 7) If there is no continuity, field coil is good. If there is continuity, field coil is bad. Replace field coil.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

BRUSH HOLDER & SPRING

1. Check for smooth movement of brush in brush holder. If movement is sluggish, inspect holder for distortion and contamination. Clean, repair or replace as necessary.
2. Check for continuity across insulated (positive side) brush holder and grounded (negative side) brush holder. If there is no continuity, brush holder is good. If there is continuity, insulation is bad. Replace brush holder as an assembly.

SOLENOID

Note. Perform tests with starter assembled and field lead from starter disconnected at solenoid.

Pull-In Coil Open Circuit Test

Using an ohmmeter, check for continuity between solenoid "S" and "M" terminals. If continuity is present, coil is good. If no continuity exists, replace solenoid.

Pull-In Test

Connect test leads to starter. (Scheme 8) Connect negative battery lead to starter housing and "M" terminal. Connect positive battery lead to "S" terminal. If starter pinion gear does not move out, replace solenoid.

Scheme 8

Hold-In Open Coil Circuit Test

Check for continuity between solenoid "S" terminal and solenoid housing. If continuity is present, coil is good. If continuity does not exist, replace solenoid.

Hold-In Test

Connect test leads to starter as in PULL-IN TEST. (Scheme 8) Disconnect negative lead from "M" terminal. Starter pinion gear should stay out. If pinion gear does not stay out, replace solenoid.

Armature Shaft Bushing

Inspect bushings for excessive scratching or other signs of wear. Check for signs of burning or other damage. Replace as necessary.

Brushes

1. Using a micrometer, measure brushes for wear. On Samurai, standard measurement is .67" (17 mm). Minimum measurement is .45" (11.5 mm). On Sidekick and Swift GT (A/T), and all other Swift models with reduction type starters, standard measurement is .69" (17.5 mm). Minimum measurement is .47" (12 mm).
2. On Swift GT (M/T) minimum measurement is .35" (9. mm). On all models if less than minimum, replace brushes.

1. Check for smooth movement of brush in brush holder. If movement is sluggish, inspect holder for distortion and/or contamination. Clean, repair or replace as necessary.
2. Inspect brush spring for wear, damage or other abnormal conditions. Using a spring tension gauge, check tension of brush spring. On Samurai, standard tension is 3.53 lbs. (1.6 kg) and minimum tension is 2.2 lbs. (1.0 kg). On Sidekick and Swift GT (A/T), standard tension is 4.32 lbs. (1.96 kg) and minimum tension is 1.54 lbs. (0.7 kg). On Swift standard models, standard tension is 4.63 lbs. (2.1 kg) and minimum tension is 1.54 lbs (0.7 kg). If tension is less than minimum specification, replace brush spring.

Note. On Swift GT (M/T), replace brush holder and spring as an assembly.

Commutator

1. Inspect commutator for dirt or signs of burning. If dirt or burning is present, sand lightly with No. 300-400 sand paper or turn on lathe as necessary to clean surface.
2. Using a dial indicator, check commutator for runout. Standard runout is.0019" (.05 mm) or less. Maximum runout is.016" (.4 mm). If runout exceeds maximum limit, replace commutator.
3. Using a micrometer, measure diameter of brush end of commutator. On Samurai, standard measurement is 1.26" (32 mm). Minimum measurement is 1.22" (31 mm). On Sidekick, Swift and Swift GT (A/T), standard measurement is 1.14" (29 mm). Minimum measurement is 1.13" (28.8 mm). On all Swift GT (M/T), minimum measurement is 1.06" (27 mm). If measurement is less than minimum, replace commutator.
4. Measure depth of insulator grooves between commutator segments. (Scheme 9) On Samurai, standard depth is.016-.024" (.4-.6 mm). Minimum depth is.0078" (.2 mm). On Sidekick, Swift and Swift GT (A/T), standard depth is.0196-.031" (.5-.8 mm). Minimum depth is.0078" (.2 mm). On all Swift GT (M/T), minimum depth is.0078" (.2 mm). If measurement is less than minimum depth, replace commutator.

Scheme 9

Drive Lever Yoke

Inspect all pivot points for excessive wear. If any pivot or engagement points show excessive wear, replace drive lever.

Pinion

1. Inspect pinion for wear or damage. Ensure clutch locks up when turned in direction of drive and rotates easily and smoothly in reverse direction. Replace as necessary.
2. Check teeth for wear or damage. Check pinion for smooth movement. Replace as necessary.

Scheme 10

Scheme 11

1. Lubricate all friction surfaces. On reduction type starter, install center bearing and shock absorber assembly onto planetary carrier shaft, and install circlip. (Scheme 10) On all models, install overrunning clutch, pinion stop ring and snap ring (if removed). Install brushes into brush holder.
2. On reduction type starter, install shaft assembly and lever. Install seal rubber and plate. Install gasket and gears. On all models, install armature, yoke and brush holder into starter housing, matching reference marks scribed during disassembly. Place commutator cover over starter housing.
3. On conventional type starter, install armature plate and brake spring. (Scheme 11) On all models, install 2 bolts and 2 screws holding commutator cover to starter housing. Align solenoid with scribe marks and install on starter housing.
4. Install and tighten 2 solenoid-to-starter housing screws. Install starter housing field coil lead-to-solenoid terminal and tighten retaining nut.