2005 SUZUKI JIMNY Switch

Downloaded from www.Manualslib.com manuals search engine 6G-6 CRANKING SYSTEM
DISASSEMBLY AND REASSEMBLY
NOTE:
Make sure to apply grease before assembly, where are indicated “A” in the figure below.
Spare parts have been lubricated.
1. Front housing 6. Over-running clutch 11. Magnetic switch 16. Packing 21. Rear bracket
2. Bush 7. Lever 12. Ball 17. Yoke 22. Rear bush
3. Snap ring 8. Plunger 13. Internal gear 18. Armature 23. Brush spring
4. Pinion stop ring 9. Plate 14. Planetary carrier shaft 19. Brush Apply grease (99000-25010)
5. Pinion gear 10. Seal rubber 15. Planetary gear 20. Brush holder Do not reuse.

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-7
Specifications
Voltage 12 volts
Output 0.9 kW 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length 12.3 mm (0.48 in.) 12.3 mm (0.48 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at
20° C (68 °F)No load characteristic 11.0 V90 A maximum
2,800 rpm minimum90 A maximum
2,500 rpm minimum
Load characteristic8.0 V
200 A4.8 N·m (0.48 kg-m,
3.5 lb-ft) minimum
1,260 rpm minimum–
7.5 V
300 A–10.5 N·m (1.05 kg-m,
7.6 lb-ft) minimum
880 rpm minimum
Locked rotor current3.5 V550 A maximum
12.2 N·m (1.22 kg-m,
8.8 lb-ft) minimum–
4.0 V–760 A maximum
19.5 N·m (1.95 kg-m,
14.1 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7D
7E
7F
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
7A
6H
7B1
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Battery .......................................................... 6H-2
Generator ..................................................... 6H-4
Diagnosis ........................................................ 6H-6
Battery .......................................................... 6H-6
Generator ..................................................... 6H-7
On-Vehicle Service......................................... 6H-9
Battery .......................................................... 6H-9
Jump starting in case of emergency......... 6H-9
Dismounting ........................................... 6H-11
Handling ................................................. 6H-11
Remounting ............................................ 6H-11Generator ................................................... 6H-11
Generator belt ........................................ 6H-11
Unit Repair Overhaul ................................... 6H-12
Generator ................................................... 6H-12
Dismounting ........................................... 6H-12
Remounting ............................................ 6H-13
Disassembly and reassembly ................ 6H-13
Inspection ............................................... 6H-14
Specifications............................................... 6H-17
Battery........................................................ 6H-17
Generator ................................................... 6H-17
Tightening Torque Specification ................ 6H-17

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).

Downloaded from www.Manualslib.com manuals search engine 6H-4 CHARGING SYSTEM
When keeping battery on vehicle over a long period of time, follow
instructions given below.
Weekly, start the engine and run it until it reaches normal
operating temperature with engine speed of 2,000 to 3,000
rpm. Make sure all electric switches are off before storing the
vehicle.
Recharge the battery twice a month to prevent it from dis-
charging excessively. This is especially important when
ambient temperature is low.
The battery discharges even when it is not used, while vehi-
cles are being stored. Battery electrolyte can freeze and bat-
tery case can crack at cold ambient condition if battery is not
properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) termi-
nal post, tend to become corroded. The product of corrosion,
or rust, on the mating faces of conductors resists the flow of
current.
Clean the terminals and fittings periodically to ensure good
metal-to-metal contact, and grease the connections after
each cleaning to protect them against rusting.
3) Be always in the know as to the state of charge of the bat-
tery. The simplest way to tell the state of charge is to carry
out a hydrometer test. The hydrometer is an instrument for
measuring the specific gravity (S.G.) of the battery electro-
lyte. The S.G. of the electrolyte is indicative of the state of
charge. Refer to “HYDROMETER TEST” in this section.
Generator
The generator is a small and high performance type with an IC regulator incorporated.
The internal components are connected electrically as shown below figure.
The generator features are as follows:
Solid state regulator is mounted inside the generator.
All regulator components are enclosed into a solid mold.
This unit along with the brush holder assembly is attached to the rear housing.
The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the volt-
age setting cannot be adjusted.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two
brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal con-
ditions will provide long period of attention-free service.
The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.
A condenser mounted in the rear housing suppresses radio noise.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-5
1. Generator with regulator assembly 3. Stator coil 5. Field coil (rotor coil) 7. Main switch
2. I.C. regulator 4. Diode 6. Charge indicator light 8. Battery
1. Pulley 5. Stator core 9. Front housing IG: Ignition terminal
2. Pulley nut 6. Field coil 10. Rear housing L: Lamp terminal
3. Rotor fan 7. Regulator B: Generator output (Battery terminal)
4. Stator coil 8. Brush E: Ground

Downloaded from www.Manualslib.com manuals search engine 6H-8 CHARGING SYSTEM
UNDERCHARGED BATTERY
This condition, as evidenced by slow cranking or indicator clear
with red dot can be caused by one or more of the following condi-
tions even though indicator lamp may be operating normal.
Following procedure also applies to cars with voltmeter and
ammeter.
1) Make sure that undercharged condition has not been caused
by accessories left on for extended period of time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to BATTERY section.
4) Inspect wiring for defects. Check all connections for tight-
ness and cleanliness, battery cable connections at battery,
starting motor and ignition ground cable.
5) Connect voltmeter and ammeter as shown in the figure.
6) Measure current and voltage.
No-load Check
1) Run engine from idling up to 2,000 rpm and read meters.
Standard current
10 A maximum
Standard voltage
14.4 – 15.0 V (at 20 °C, 68 °F)
Higher Voltage
If voltage is higher than standard value, check ground of brushes.
If brushes are not grounded, replace IC regulator.
Lower Voltage
If voltage is below or in standard value, increase engine speed up
to 2,000 – 2,500 rpm soon after starting engine, and read maxi-
mum value on ammeter immediately.
If current is less than 49 A, repair or replace generator.NOTE:
Use fully charged battery.
1. Generator
2. Ammeter (between generator (B) terminal and battery (+) terminal)
3. Voltmeter (between generator (B) terminal and ground)
4. Battery
5. Load
6. Switch
NOTE:
Turn off switches of all accessories (wiper, heater etc.).
NOTE:
Consideration should be taken that voltage will differ
somewhat with regulator case temperature as shown in
the graph.