Starters: Other Suzuki Vitara I

CRANKING CIRCUIT

Note. Starting motor vary depending on specifications. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts (Grand Vitara, Vitara).

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

STARTING MOTOR CIRCUIT

The magnetic switch coils are magnetized when the ignition switch is closed. The resulting plunger (2) and pinion drive lever (1) movement causes the pinion to engage the engine flywheel gear and the magnetic switch (4) main contacts to close, and cranking takes place. When the engine starts, the pinion overrunning clutch (7) protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. (Scheme 31)

Scheme 31

ARMATURE

1. Inspect commutator for dirt or burn. (Scheme 32) Correct with sandpaper or lathe as necessary.
2. Check commutator for uneven wear with the armature (1) supported on V-blocks (2). (Scheme 33) If deflection of dial gauge (4) pointer exceeds limit, repair or replace. See «STARTER SPECIFICATIONS»(ref-163798-S15586539982004071300000)
3. Inspect the commutator for wear. (Scheme 34) If diameter is below limit, replace the armature.
4. Inspect the commutator (1) for insulator (2) depth. (Scheme 35) Correct or replace if it is below the service limit.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

ARMATURE SHAFT BUSHING

Inspect bushing for wear or damage. (Scheme 36) Replace if necessary.

Scheme 36

BRUSHES & BRUSH HOLDER

1. Check brushes for wear. (Scheme 37) Measure length of brushes and if it is below the service limit, replace the brush. See «STARTER SPECIFICATIONS»(ref-163798-S15586539982004071300000). Install brushes to each brush holder and check for smooth movement.
2. Check movement of brush in brush holder. (Scheme 38) 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 holder (positive side) and grounded brush holder (negative side). If continuity exists, brush holder is grounded due to defective insulation and should be replaced.

Scheme 37

Scheme 38

FRONT HOUSING BUSHING

Inspect the bushing for wear or damage. (Scheme 39) Replace if necessary.

Scheme 39

GEARS

Inspect the internal gear and the planetary gears for wear, damage or other abnormal conditions. (Scheme 40) Replace if necessary.

Scheme 40

MAGNETIC SWITCH

Push in plunger and release it. The plunger should return quickly to its original position. (Scheme 41) Replace if necessary.

Scheme 41

PINION & OVERRUNNING CLUTCH

Inspect the 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. (Scheme 42) Replace if necessary. Inspect the spline teeth for wear or damage. (Scheme 43) Replace if necessary. Inspect the pinion for smooth movement.

Scheme 42

Scheme 43

PLUNGER

Inspect plunger for wear. (Scheme 44) Replace if necessary.

Scheme 44