SUZUKI GRAND VITARA 1987 Service Repair Manual

8-3. IMPORTANT REMINDERS FOR
INSTALLATIONDistributor
When re-installing distributor, be sure to insertit into distributor gear case in the following
sequence:
1. Turn over crankshaft in normal direction (clockwise as viewed from crankshaft pulley
side) until specified timing mark @on flywheel aligns with timing match mark
0.
CAUTION :
After aligning two marks, remove cylinder
head cover to visually confirm that rocker
arms are not riding on camshaft cams at
No. 1 cylinder. If arms are found to be
riding on cams, turn over crankshaft 360”
to align two marks anew.
lO’(B.T.D.C.1timing mark
mark
Fig.
2. Remove distributor cap, and turn rotor to make center of rotor align with cap clamp
center on distributor housing as shown in
figure.
1. Rotor
Fig. 8-27 3. Center of rotor
2. Housing and clamp
3. Insert distributor into gear case in such a way that center of distributor flange will coincide
with the distributor mounting screw holeprovided in distributor gear case. When distributor is inserted properly, position of
distributor rotor becomes as shown in figure.
Secure distributor in place tentatively by
making mounting screw finger-tight.
Fig. 8-28 1. Distributor flange 3. Rotor
2. Mounting screw
4. Install cap gasket and distributor cap to
distributor. Hook 2 clamps securely.
5. Distribute cords as shown in figure. Securely
connect cords to distributor cap terminals and
spark plugs.
NOTE:
Make sure to clamp high tension cords so that
they do not contact other parts.
1. No. 1 cylinder 3. No. 3 cylinder
2. No. 2 cylinder 4. No. 4 cylinder
Fig. 8-29 High tension cords distribution
6. Connect vacuum hose to vacuum controller,
and coupler of lead wires.
7. Connect negative cable at battery.
8. Start engine and adjust ignition timing by
using timing light as previously outlined.
After adjustment, tighten distributor flange
bolt.
8-11

SECTION 9
CRANKING SYSTEM
GENERAL DESCRIPTION.,.....,...........................,9-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
LUBRICATION9-5
9-1.
9-2.
9-3.
9-4.
9-5.
REMOVAL AND INSTALLATION.............................9-5
DISASSEMBLY............................................ 9-6
STARTING MOTOR INSPECTION.............................9-7
COMMUTATOR...........................................9-7
FIELD COIL............................................. 9-8
9-7.
9-8.
CONTENTS
BRUSH................................................. 9-8
BRUSH HOLDER AND SPRING............................... 9-9
DRIVE LEVER........................................... 9-9
PINION................................................. 9-9
ARMATURE SHAFT BUSH.................................. 9-9
MAGNETIC SWITCH......................................9-10
PERFORMANCE TEST.....................................9-11
PULL-IN TEST...........................................9-11
HOLD-IN TEST..........................................9-11
PLUNGER RETURN......................................9-11
PERFORMANCE TEST....................................9-11
CLUTCH SWITCH........................................ 9-12
9
9-6.
9-1

9-1. GENERAL DESCRIPTION
To distributorMagnetic switch
Pull in coil
Hold in coil
I I
Magnetic switch contacts
Plungerhclutch. . . ..i+rh
Pin
h n
Pinion 84 Over running
clutchStarting motor
Fig. 9 1 Cranking circuit
CRANKING CIRCUIT
The cranking circuit consists of the battery, starting motor, ignition switch, clutch switch and related
electrical wiring. These components are connected electrically as shown in Fig. 9-l. Only the starting
motor will be covered in this portion.
STARTING MOTOR
The starting motor consists of parts shown in Fig. 9-2 and has field coils mounted in starting motor yoke
(frame).
The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they
will be protected against possible dirt and water splash.
In the circuit shown in Fig. 9-1, the magnetic (motor) switch coils are magnetized when the ignition
switch is closed. The resulting plunger and pinion drive lever movement causes the pinion to engage the
engine flywheel gear and the magnetic switch main contacts to close, and cranking takes place. When the
engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch
is opened, at which time the return spring causes the pinion to disengage.
9-2

BAa7
1 IId916156
1. Drive housing cover
2.Drive bushing3.Drive housing
4.Armature ring
5. Armature stop ring6.Over-running clutch7. Pinion drive lever
8.Magnetic switch
9. Commutator end cover10.Brush spring11.Brush holder12.Brush
13.Washer
14. Commutator end bushing18.Armature
16. Starting motor yoke
A : Hold-in coilB : Pull-in coil
9-3

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