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CRANKING SYSTEM 6G-1
6F1
6F2
6H
6K
6G
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6G
CRANKING SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................. 6G-2
CRANKING CIRCUIT ................................... 6G-2
DIAGNOSIS ..................................................... 6G-2
DIAGNOSIS TABLE ..................................... 6G-2
PERFORMANCE TEST ............................... 6G-4
PULL-IN TEST ......................................... 6G-4
HOLD-IN TEST ........................................ 6G-4
PLUNGER AND PINION RETURN TEST 6G-4
NO-LOAD PERFORMANCE TEST .......... 6G-5ON-VEHICLE SERVICE ...................................6G-5
STARTING MOTOR .....................................6G-5
DISMOUNTING.........................................6G-5
REMOUNTING..........................................6G-5
DISASSEMBLY AND REASSEMBLY .......6G-6
SPECIFICATION ..............................................6G-8
1.0 kW TYPE.............................................6G-8
1.2 kW TYPE.............................................6G-8
REQUIRED SERVICE MATERIAL...................6G-8
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to AIR BAG SYSTEM COMPONENTS and WIRING LOCATION VIEW
under DIAGNOSIS in air bag system section in order to confirm whether you are performing service
on or near the air bag system components or wiring. Please observe all WARNINGS and SERVICE
PRECAUTIONS under PRECAUTIONS in air bag system section before performing service on or
around the air bag system components or wiring. Failure to follow WARNINGS could result in unin-
tentional activation of the system or could render the system inoperative. Either of these two condi-
tions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Starting motor varies depending on specifications, etc. Therefore, be sure to check model and speci-
fication of the vehicle being serviced before replacing parts.
Page 680 of 698
6G-8 CRANKING SYSTEM
SPECIFICATION
1.0 kW TYPE
1.2 kW TYPE
REQUIRED SERVICE MATERIAL
Voltage 12 volts
Output 1.0 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 14.0 mm (0.55 in.) Limit: 9.0 mm (0.35 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20°C
(68°F)No load characteristic 11.5 V90 A maximum
3,000 rpm minimum
Load characteristic8.7 V
230 A6.9 N·m (0.69 kg-m, 5.0 lb-ft) minimum
1130 rpm minimum
Locked rotor current 2.5 V325 A maximum
8.2 N·m (0.82 kg-m, 6.0 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.27 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20°C
(68°F)No load characteristic 11.0 V90 A maximum
2,500 rpm minimum
Load characteristic7.5 V
300 A10.5 N·m (1.05 kg-m, 7.59 lb-ft) minimum
880 rpm minimum
Locked characteristic 4.0 V760 A maximum
19.5 N·m (1.95 kg-m, 14.1 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Front and rear bush (for 1.2 kW
type only)
Plunger
Pinion drive lever
Internal gear
Planetary carrier shaft
Planetary gear
Ball
Page 681 of 698
CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7A
6H
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................. 6H-2
BATTERY ..................................................... 6H-2
CARRIER AND HOLD-DOWN ................. 6H-2
ELECTROLYTE FREEZING .................... 6H-2
SULFATION ............................................. 6H-2
BUILT-IN INDICATOR (IF EQUIPPED) ... 6H-2
CARE OF BATTERY ................................ 6H-3
GENERATOR .............................................. 6H-4
DIAGNOSIS ..................................................... 6H-5
BATTERY ..................................................... 6H-5
VISUAL INSPECTION.............................. 6H-5
HYDROMETER TEST.............................. 6H-5
GENERATOR .............................................. 6H-6
CHARGING INDICATOR LAMP
OPERATION ............................................ 6H-6
UNDERCHARGED BATTERY ................. 6H-7
OVERCHARGED BATTERY.................... 6H-8ON-VEHICLE SERVICE .................................. 6H-9
BATTERY .................................................... 6H-9
JUMP STARTING IN CASE OF
EMERGENCY .......................................... 6H-9
DISMOUNTING...................................... 6H-10
HANDLING............................................. 6H-10
REMOUNTING....................................... 6H-10
GENERATOR ............................................ 6H-10
GENERATOR BELT .............................. 6H-10
DISMOUNTING AND REMOUNTING ... 6H-11
DISASSEMBLY AND REASSEMBLY .... 6H-11
INSPECTION ......................................... 6H-12
SPECIFICATION ........................................... 6H-14
BATTERY .................................................. 6H-14
GENERATOR ............................................ 6H-14
TIGHTENING TORQUE SPECIFICATION.... 6H-14
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
Page 694 of 698
6H-14 CHARGING SYSTEM
SPECIFICATION
BATTERY
GENERATOR
TIGHTENING TORQUE SPECIFICATION
NOTE:
The battery used in each vehicle is one of the following two types, depending on specification.
Battery type 38B20L 55B24L
Rated capacity AH/5HR, 12 Volts 28 38
Electrolyte L (US/Imp. pt) 2.1 (4.44/3.70) 2.8 (5.92/4.93)
Electrolyte S.G. 1.28 when fully charged at 20°C (68°F)
Type 75 A type
Rated voltage 12 V
Nominal output 75 A
Permissible max. speed 18000 r/min.
No-load speed 1020 r/min (rpm)
Setting voltage 14.2 to 14.8 V
Exposed brush length Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.06 in.)
Permissible ambient temperature–30 to 90°C (–22 to 194°F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Nm kg-m lb-ft
Body ground bolt 8 0.8 6.0
Generator bolts 23 2.3 16.5
“B” terminal inner nut 4.2 0.42 3.0
“B” terminal outer nut 8 0.8 6.0
Pulley nut 111 11.1 80.5
Rear end frame nuts 4.5 0.45 3.5
Rear end cover nuts 4.5 0.45 3.5
Rectifier “B” bolt 3.9 0.39 3.0
Stator stud bolts 8.8 0.88 6.5
Drive end bearing plate screws 2.6 0.26 2.0
Rectifier screws 2.0 0.20 1.5
Regulator and brush holder screws 2.0 0.20 1.5
Terminal plate bolt 3.8 0.38 3.0