Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 199

1I-4 Starting System: For Petrol Engine Model

Hold-In Test

1) While connected as above with plunger out, disconnect negative lead (2) from terminal “M” (1).
2) Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch.

Plunger and Pinion Return Test

1) Disconnect negative lead (1) from switch body (2).
2) Check that plunger and pinion return inward. If plunger and pinion don’t return, replace the magnetic switch.

No-Load Performance Test

1) Connect battery and ammeter to starter as shown.
2) 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

NOTE
Use wires as thick as possible and tighten each terminal fully.

 

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Starting System: For Petrol Engine Model 1I-5

Repair Instructions

Starting Motor Dismounting and Remounting

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Dismounting

1) Disconnect negative (–) battery lead at battery.
2) Hoist vehicle
3) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
4) Remove starting motor mount bolts (3).
5) Remove starting motor (4).

Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (5) to specified torque.

Tightening torque
Starting motor battery cable nut (a):  11 N·m (1.1 kgf-m, 8.0 lb-ft)

(a)

(c)

(a)

(b)

(b)

[A]

[B]

3

3

4

5

4

5

2

1

3

1

2

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[A]: For M16 Engine

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

[B]: For J20 Engine

: 25 N

⋅m (2.5 kgf-m, 18.5 lb-ft)

1I-6 Starting System: For Petrol Engine Model

Starting Motor Components

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The starting motor consists of parts shown in below and has permanent magnets 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.

NOTE
Spare parts have been lubricated.

 

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1. Front housing

7. Plate

13. Planetary gear

19. Rear bush

2. Bush

8. Seal rubber

14. Packing

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

3. Pinion stop ring

9. Magnetic switch

15. Yoke

: Do not reuse.

4. Over-running clutch

10. Starting motor battery cable nut

16. Armature

: Apply grease 99000-25010 to sliding surface of each part.

5. Lever

11. Internal gear

17. Brush assembly

6. Plunger

12. Planetary carrier shaft

18. Rear bracket

Starting System: For Petrol Engine Model 1I-7

Starting Motor Inspection

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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 
and “M” terminal. If no continuity exists, coil is open and 
should be replaced.

Hold-In coil open circuit test
Check for continuity across magnetic switch “S” terminal 
and coil case. If no continuity exists, 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: 5.5 mm (0.22 in.)

• Install brushes to each brush holder and check for 

smooth movement.

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