1987 SUZUKI GRAND VITARA Service Repair Manual

INSPECTIONStator
Rotor
1) Check rotor for no open circuits
Using an ohmmeter, check for continuity
between slip rings.
Fig. lo-12
Standard resistance2.8 - 3.0 !aI
If there is no continuity, replace rotor.
2) Check rotor for no grounds.
Using an ohmmeter, check that there is no
continuity between slip ring and rotor.
If there is continuity, replace rotor.
Fig. 10-13
1) Check stator for no open circuits
Using an ohmmeter, check all leads for con-
tinuity. If there is no continuity, replace
stator.
Fig. 1014
2) Check stator for no grounds
Using an ohmmeter, check that there is no
continuity between coil leads and stator core.
If there is continuity, replace rotor.
Fig. 1015
3) Inspect slip rings
Check slip rings for roughness or scoring. If
rough or scored, replace rotor.
10-8

Brush and Brush holder
Check each brush for wear by measuring its
length as shown. If brush is found worn down to
service limit, replace brush with holder.
Brush lengthStandardService limit
11 mm (0.43 in)5 mm (0.20 in)
Fig. lo-16
Rectifier
Using an ohmmeter, check continuity between
“B” terminal and ground.
Put one tester lead to terminal “B” and the
other lead to ground; then swap two leads. Of
two tester indications, one should be about
10 ohms, meaning continuity, and the other
should be infinity (non continuity).
If not, replace rectifier assembly.
Condenser
Check condenser capacity in regulator.
Fig. 10-18
ICondenser capacity0.5 /JF
ASSEMBLY
Reverse disassembly procedure, using care on
following points.
1) Use a press when forcing bearing into rotor
shaft or drive end frame.
Fig. lo-19
e: Battery terminal
E: Earth
Fig. 10-17
2) Alternator pulley tightening torque.
Tightening torque
50-65N-m15.0-6.5kpm137-47lb-ft
10-9

3) Make sure to assemble stator terminal
insulator properly.
10-2. BATTERY
1. Stator terminal insulator
Fig. lo-20
4) Alternator V belt tension.
1. Crankshaft pulley
2. Water pump pulley
3. Alternator pulley
A :Belt deflection
Fig. 1021
Drive belt deflection
(Under 10 kg thumb
pressure)
6-9mm
(0.24 - 0.35 in)
NOTE:
Clamp brake pipe with pipe clamp on radiator
under cover after installing radiator under cover.
GENERAL DESCRIPTION
The battery has three major functions in the
electrical system. First, it is a source of electrical
energy for cranking the engine. Second it acts as
a voltage stabilizer for the electrical system. And
third, it can, for a limited time, provide energy
when the electrical load exceeds the output of
the generator.
Each new car shipped from the factory is
fitted with following battery.
IModel55BzR=l(NXIOO-S6 6))
1 Rated capacityt 137 kC (38 Ah)/5HR j
This battery is completely sealed, except for six
small vent holes in the top. These vent holes
allows the small amount of gas produced in the
battery to escape. This sealed battery has a
built-in temperature compensated indicator in
the top of the battery.
Fig. lo-22
CARE OF THE BATTERY
[Electrolyte freezing]
The freezing point of electrolyte depends on its
specific gravity. Since freezing may ruin a
battery, it should be protected against freezing
by keeping it in a fully charged condition.
10-10

[Carrier and hold-down]
The battery carrier and hold-down clamp should
be clean and free from corrosion before instal-
ling the battery. The carrier should be in good
condition so that it will support the battery
securely and keep it level.
Make certain there are no parts in carrier before
installing the battery.
To prevent the battery from shaking in its
carrier, the hold-down bolts should be tight but
not over tightened.
[Visual inspection]
Check for obvious damage, such as cracked or
broken case or cover, that could permit loss of
electrolyte. If obvious damage is noted, replace
the battery. Determine cause of damage and
correct as needed.
Check the battery terminal and cords for corro-
sion. If any, it should be cleaned.
[Built-in indicator]
This sealed battery has a built-in temperature
compensated indicator in the top of the battery.
This indicator is to be used with the following
diagnostic procedure. When observing the
indicator, make sure that the battery has a clean
top. A light may be needed in some poorly-lit
areas.
Under normal operation, two indications can
be seen
2
Clear
RedCHARGING
NECESSARY
Fig. lo-23
l Clear with Red Dot
This means the discharging battery. In this case,
charge the battery until the indicator will be
blue with red dot. The charging and electrical
systems should also be checked at this time. If
any defective is found, correct it. While charging
it, if the battery feels hot 52°C (125” F), or if
violent gassing or spewing of electrolyte through
the vent hole occurs, discontinue charging or
reduce charging rate.
[Jump starting in case of emergency with
auxiliary (booster) battery]
NOTE:
l Do not push or tow the vehicle to start.
Damage to the emission system and/or to
other parts of the vehicle may result.
8 Both booster and discharged battery should
be treated carefully when using jumper cables.
Follow the procedure outlined below, being
careful not to cause sparks:
CAUTION:
l Departure from these conditions or the
procedure below could result in: (1)
Serious personal injury (particularly to
eyes) or property damage from such
causes as battery explosion, battery acid,
or electrical burns; and/or (2) damage to
electronic components of either vehicle.
l Never expose battery to open flame or
electric spark-batteries generate a gas
which is flammable and explosive.
l Remove rings,watches,and other
jewelry. Wear approved eye protection.
l Do not allow battery fluid to contact
eyes, skin, fabrics, or painted surfaces -
fluid is a corrosive acid. Flush any con-
tacted area with water immediately and
thoroughly. Be careful that metal tools
or jumper cables do not contact the
positive battery terminal (or metal in
contact with it) and any other metal on
the car, because a short circuit could
occur. Batteries should always be kept
out of the reach of children.
1) Set parking brake and place transmission in
neutral. Turn off the ignition, turn off lights
and all other electrical loads.
2) Check electrolyte level. If level is below low
level line, replace battery.
NOTE:
When jump starting an engine with charging
equipment, be sure equipment used is 12volt
and negative ground. Do not use 24volt charging
equipment. Using each equipment can cause
serious damage to the electrical system or
electronic parts.
10-11

3) Attach the end of one jumper cable to the
positive terminal of the booster battery and
the other end of the same cable to the positive
terminal of the discharged battery. Do not
permit vehicles to touch each other as this
could cause a ground connection and counte-
ract the benefits of this procedure. (Use
12-volt battery only to jump start the engine).
4) Attach one end of the remaining negative
cable to the negative terminal of the booster
battery, and the other end to a solid engine
ground (such as A/C compressor bracket or
generator mounting bracket) at least 18 inches
from the battery of the vehicle being started
(DO NOT CONNECT DIRECTLY TO THE
NEGATIVE TERMINAL OF THE DEAD
BATTERY).
5) Start the engine of the vehicle that is provid-
ing the jump start and turn off electrical
accessories. Then start the engine in the car
with the discharged battery.
6) Reverse these directions exactly when remov-
ing the jumper cables. The negative cable
must be disconnected from the engine that
was jump started first.
REMOVE AND REPLACE
When handling a battery, the following safety
precautions should be followed:
1) Hydrogen gas is produced by the battery.
A flame or spark near the battery may cause
the gas to ignite.
2) Battery fluid is highly acidic. Avoid spilling
on clothing or other fabric. Any spilled
electrolyte should be flushed with large
quantity of water and cleaned immediately.
To remove or replace a battery, always
disconnect the negative cable first, then the
positive cable.
BATTERY CABLES
Connect battery cables as shown in the figure
below and make sure to properly tighten all
terminals.
1. Battery ground
2. Starter cable
4.Fusible link
cable
Fig. IO-24
5. Wiring harness No. 2
10-12

SECTION 11
CLUTCH
CONTENTS
11-l. GENERAL DESCRIPTION..................................11-2
11-2. REMOVAL.............................................
11-3. INSPECTION OF COMPONENTS11-5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .11-7
11-5.MAINTENANCk SERVICES................................. 11-8
RECOMMENDED TORQUE SPECIFICATION.................. 11-10
..............................
11-2
11-4
11-6
11
11-1

11-l. GENERAL DESCRIPTIONThe clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering-
finger type, which is a solid ring in the outer diameter part, with a series of tapering fingers pointing
inward. The disc, carrying four torsional coil springs, is slidably mounted on the transmission input shaft
with a serration fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the
peripheral edge of the spring pushes on the pressure plate against the flywheel (with the disc in between),
when the clutch release bearing is held back: Tnis is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing to advance and push on the tips of the tapering
fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to trans-
mission input shaft.
Flywheel
Crankshaft
Clutch disc.
Transmission
Fig. 11-l
11-2

1.Clutch disc7.
No. 2 bushing
2. Clutch cover 8.
Clutch release shaft
3. Lock washer 9.
Return spring
4. Cover bolt 10.
No. 1 bushing
5.Clutch releasebearing11.Shaft seal
8.
Clutch release fork pin 12. Shaft cowr
Fig. 1 l-2
11-3