1987 SUZUKI GRAND VITARA Service Repair Manual

9-2. SPECIFICATIONS
Voltage12 volts
output0.9 kW
Rating30 seconds
Direction of rotationClockwise as viewed from pinion side
Brush length17 mm (0.67 in.)
Number of pinion teeth
No-load characteristic
6
60 A maximum at 11.5 volts, 6,600 r/min minimum
ILoad characteristic150 A maximum at 9 volts and 0.29 kg-m torque,
1.900 r/min minimum,
500A maximum at-5 volts, 1.15 kg-m minimum
8 volts maximum
Locked rotor current
Magnetic switch operating voltage
9-4

9-3. LUBRICATION9-4. REMOVAL AND INSTALLATION
The starting motor does not require lubrication
except during overhaul.
When the motor is disassembled for any reason,
lubricate as follows:
Grease
Bearing grease
SUZUKI SUPER GREASE A
99ooo-25010
Use following procedure to remove starter:
1) Disconnect negative battery lead at battery.
2) Disconnect magnetic switch lead wire
(BLACK/YELLOW) and battery cable from
starting motor terminals.
3) Remove two starting motor mount bolts.
4) Remove starting motor.
5) To install, reverse the above procedure.
Fig. 54 Starting motor mounting
Fig. 9-3 Starting motor greasing poin t
9-5

9-5. DISASSEMBLY
NOTE:
Before disassembling starting motor, be sure to
put match marks at two tocations ( @ and @I )
as shown in the figure below so that any possible
mistakes can be avoided.
/Commutator endcover
Fig. 95
1) Remove nut securing the end of field coil
lead to terminal on the head of magnetic
switch.
Fig. 9-6
2) Take off magnetic switch @ from starting
motor body by removing two mounting
screws.
3) Loosen 2 bolts and 2 screws to remove
commutator end cover.
4) Separate drive housing and armature from
yoke.
Fig. 9-8
5) Draw brushes out of holder.
Fig. 49
6) Draw off over running clutch, as follows:
(1)
(2)
Draw stop ring @ toward clutch side.
Remove armature ring @ and slide off
clutch.
r;)(‘lutch Pinion
Fig. 910
9-6

96. STARTING MOTOR INSPECTION
1) Inspect Commutator
Inspect commutator for dirt or burn. Correct
with sandpaper or lathe, if necessary.
#300-400
.
Fig. 9- 11
Check commutator for uneven wear. If deflec-
tion of dial gauge pointer exceeds limit, repair
or replace.
NOTE:
Below specification presupposes that armature is
free from bend. Bent shaft must be replaced.
Commutator
out of round
StandardLimit
0.05 mm (0.0019 in.)0.4 mm
or less(0.015 in.)
Inspect commutator for wear. If below limit,
replace armature.
StandardLimit
Co;ye;tor outside32 mm31 mm
(1.26 in.)(1.22 in.)
Fig. 9- 13
Inspect commutator for mica depth. Correct or
replace if below limit.
Commutator
mica depth
StandardLimit
0.4 - 0.6 mm0.2 mm
(0.015 - 0.023 in.)(0.0076 in.)
0.4 - 0.6 mm(0.015 - 0.023 in.)
InsulatorCommutator
CORRECT
Fig. 912INCORRECT
Fig. 9 14
9-7

Ground test
Check commutator and armature coil core. If
there is continuity, armature is grounded and
must be replaced.
Fig. 915
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.
Fig. 9 16
2) Inspect Field Coil
Open circuit test
Check for continuity between brush and bare
surface. If there is continuity, field windings are
grounded. The field coil must be replaced.
Fig. 917
3) Inspect Brush
Check brushes for wear. If below limit, replace
brush.
Brush length~~
Fig. 918
9-8

4)Inspect Brush Holder and Spring
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.
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.
Fig. 9 19
Inspect brush spring for wear, damage or other
abnormal conditions. Replace if necessary.
Brush
spring
tension
Fig. 920
5) Inspect Drive Lever
Inspect drive lever for wear. Replace if necessary.
0) Inspect Pinion
Inspect pinion for wear, damage or other ab-
normal conditions. Check that clutch locks up
when turned in direction of drive and rotates
smoothly in reverse direction. Replace if neces-
sary.
Fig. 9-22
Inspect spline teeth for wear or damage. Replace
if necessary. Inspect pinion for smooth move-
men t.
Fig. 923
7)Inspect Armature Shaft Bush
Inspect bushes for wear or damage. Replace if
Fig. 921Fig. 9-24
9-9

8) Inspect Magnetic SwitchHold in coil open circuit test
Push in plunger and release it. The plungerCheck for continuity across magnetic switch ‘S’
should return quickly to its original position.terminal and coil case. If no continuity exists,
Replace if necessary.the coil is open and should be replaced.
Fig. 925
Pull-in coil open circuit test
Check for continuity across magnetic switch
‘s’ terminal and ‘M’ terminal. If no continuity
exists, the coil is open and should be replaced.
Fig. 926
Fig. 927
REASSEMBLY
Reverse disassembly procedure, using care on
following points.
l When installing pinion drive lever, refer to
Fig. g-2 for its installation direction.
0. When installing brush holder, be careful of
brush position.
2
3
1. Brush holder
2. Yoke
3. Brush positions
Fig. 9-27- 1
9-10

9-7. PERFORMANCE TEST
IMPORTANT:
These tests must be performed within 3 -
5 seconds to avoid burning out the coil.
3) Check Plunger Return
Disconnect negative lead from switch body.
Check that plunger returns inward.
If plunger does not return, replace magnetic
switch.
1) Pull-in Test
Connect battery to magnetic switch as shown.
Check that plunger moves outward.
If plunger does not move, replace magnetic
switch.
Fig.
Before’testing,disconnect fieldcoil lead fromterminal M
w
9-28
2) Hold-in Test
While connected as above with plunger out,
disconnect negative lead from terminal M.
Check that plunger remains out.
If plunger returns inward, replace magnetic
switch. ’
Fig. 930
4) No-load Performance Test
a)Connect battery and ammeter to starter as
shown.
b) Check that starter rotates smoothly and
steadily with pinion moving out. Check that
ammeter reads the specified current.
Specified current
Less than 60 A at 11.5 V
Fig. 931
Fig. 929
9-11