2006 SUZUKI SX4 Switch

Downloaded from www.Manualslib.com manuals search engine 1I-3 Starting System:
Cranking System TestS6RW0D1904002
CAUTION!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test
Connect battery to the magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace the magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M” (2).

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch.Plunger and Pinion Return Test
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
90 A MAX. at 11 V Starting motor does not
stop runningFused contact points of magnetic switchReplace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition
switchReplace. Condition Possible cause Correction / Reference Item
1. Terminal “S”
3. Lead wire (switch to motor)
I2RH01190002-01
I2RH01190003-01
I2RH01190004-01
I2RH01190005-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS6RW0D1906001
Dismounting
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS6RW0D1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature : Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25011 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-6
Starting Motor InspectionS6RW0D1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced.Hold-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear.
Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for
smooth movement.
I2RH01190008-01
I2RH01190009-01
I2RH01190010-01
I2RH01190011-01
I2RH01190012-01
I2RH01190013-01

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Front Housing Bush
Inspect the bush for wear or damage. Replace if
necessary.
Specifications
Cranking System SpecificationsS6RW0D1907002
Tightening Torque SpecificationsS6RW0D1907003
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

I2RH01190024-01
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 (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F)No load characteristic 11.0 V90 A maximum
2370 r/min minimum
Load characteristic7.5 V
300 A10.65 N⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V780 A maximum
20 N⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0)

Downloaded from www.Manualslib.com manuals search engine 1J-2 Charging System:
Care of battery
WARNING!
• Never expose battery to open flame or electric spark because of battery generate gas which is
flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.
• Keep the battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep the electrolyte up to the upper level uniformly in all cells.
• 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 2000 to
3000 rpm. Make sure all electric switches are off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery 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 (+) terminal 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 battery. 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 electrolyte. The S.G. of the electrolyte is indicative of the state of charge. Refer to “Battery Inspection”.

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-3
Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
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 conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
I6RW0D1A0002-01
1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-5
Charging Indicator Lamp Operation
Generator Test (Undercharged Battery Check)S6RW0D1A04003
This condition, as evidenced by slow cranking or low
specific gravity can be caused by one or more of the
following conditions even though indicator lamp may be
operating normal. The following procedure also applies
to cars with voltmeter and ammeter.
• Make sure that undercharged condition has not been
caused by accessories left on for extended period of
time.
• Check drive belt for proper tension.
• If battery defect is suspected, refer to “Battery
Description”.
• Inspect wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections
at battery, starting motor and ignition ground cable.
No-Load Check
1) Connect voltmeter and ammeter as shown in figure.
NOTE
Use fully charged battery.

2) Run engine from idling up to 2,000 rpm with all
accessories turned off and read meters.
If voltage is higher than standard value, check
ground of brushes.
If brushes are not grounded, replace IC regulator.
If voltage is lower than standard value, proceed to
the following check.
Specification for undercharged battery (No-load
check)
Current: 10 A
Voltage: 14.2 – 14.8 V at Hi (H) (at 25 °C, 77 °F)
Voltage: 12.5 – 13.1 V at Lo (L) (at 25 °C, 77 °F)
NOTE
Consideration should be taken that voltage
will differ somewhat with regulator case
temperature as shown in figure.

Condition Possible cause Correction / Reference Item
Charge light does not
light with ignition ON and
engine offFuse blownCheck fuse.
Indicator lamp (LED) faultyCheck BCM, combination meter and/or CAN
communication line.
Wiring connection looseTighten loose connection.
IC regulator or field coil faultyCheck generator.
Poor contact between brush and slip
ringRepair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging)Drive belt loose or wornAdjust or replace drive belt.
IC regulator or generator faultyCheck charging system.
Wiring faultyRepair wiring.
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
I2RH011A0006-01
[A]: Regulated voltage (V)
[B]: Heatsink temperature (°C)
16.0
12.0
14.2 15.3
14.8
14.2
13.3 14.8
15.0
11.0 14.0
13.0 [A]
12.5 13.6
13.1
12.5
11.613.1
[B] -30 0 25 135
H
L
I2RH0B1A0005-01