CRANKING SYSTEM_ 66-1 SECTION 6G CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION 6G.2 Brush holder ...0...eeceeee ee 8G 8 Cranking Circuit 6G-2 Amature... cece cece eee 6G 9 Starting Motor Circuit 6G.2 YOKE eee eeeceeeceeeeeeeeeeee s+ 6-10 Ea DIAGNOSIS 66-3 Over-running clutch «2.2.0... 66-10 UNIT REPAIR OVERHAUL 665 Performance Test .........eeseeeeee OGM Dismounting and Remounting 6G-6 Pullin test... 0.... cee ee eee esses 6-11 Disassembly 6o8 Hold-in test o.oo cscceeeeeeee OGM Roascombiy 6G? Pinion retum test 6G-12 Inepestion ba8 No-load performance test ........... 66-12 Plunger 68 SPECIFICATIONS 66-13 Magnetic switch 6c8 REQUIRED SERVICE MATERIAL .......6G-13, Brush 669 SPECIAL TOOL 66-1366-2_CRANKING SYSTEM. GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section STARTING MOTOR CIRCUIT © The magnetic 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 over-running clutch protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. Magnet ewion Pubkin ol Magntle switch concts Teniten 8 Pion ve lave ‘Starter sich Pion & Overurning Steg noor olderCRANKING SYSTEM 66-3 DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: © Starting motor does not run (or runs slowly) © Starting motor runs but fails to crank engine © Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..... in battery, wiring harness, (including starting motor switch), starting motor or engine. Do not remove motor just because starting motor does not run. Check following items and narrow down scope of possible causes. 1) Condition of trouble 2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals 3) Discharge of battery 4) Mounting of starting motor Condition Possible Cause Correction Motor not running | No operating sound of magnetic switch © Battery run down Recharge battery. © Battery voltage too low due to battery deterioration —_| Replace battery. © Poor contact in battery terminal connection Retighten or repiace. © Loose grounding cable connection Retighten. © Fuse set loose or blown off Tighten or replace. # Poor contacting action of ignition switch and magnetic | Replace. switch Lead wire coupler loose in place Retighten. © Open-circuit between ignition switch and magnetic | Repair. switch © Open-circuit in pullin coil Replace magnetic switch © Brushes are seating poorly or worn down Repair or replace, # Poor sliding of plunger and/or pinion Repair. ‘Operating sound of magnetic switch heard © Battery run down Recharge battery. © Battery voltage too low due to battery deterioration | Replace battery. © Loose battery cable connections Retighten. © Burnt main contact point, or poor contacting action of | Replace magnetic switch. magnetic switch © Brushes are seating poorly or worn down Repair o replace. © Weakened brush spring Replace. © Bumt commutator Replace armature. © Poor grounding of field coil Repair. © Layer short-circuit of armature Replace. © Crankshaft rotation obstructed Repair.66-4 _CRANKING SYSTEM Condi in Possible Cause Correction Starting motor running but too slow (small torque) If battery and wiring are satisfactory, inspect starting motor © Insufficient contact of magnetic switch main contacts © Layer short-circuit of armature © Disconnected, bumt or worn commutator Poor grounding of field coil Worn brushes: Weakened brush springs Burt or abnormally worn end bush Replace magnetic switch Replace. Repair commutator or replace armature. Repair. Replace brush, Replace spring Replace bush. Starting motor running, but not cranking engine ‘Worn pinion tip Poor sliding of over-running clutch Over-running clutch slipping Worn teeth of pinion gear or flywheel Replace over-running clutch. Repair. Replace over-running clutch. Replace pinion or flywheel Noise ‘Abnormally wom bush ‘Worn pinion or worn teeth of pinion gear Poor sliding of pinion (failure in return movement) Lack of oil in each part Replace bush Replace pinion or flywheel. Repair or replace, Lubricate, Starting motor does not stop run hing Fused contact points of magnetic switch Short-circuit between turns of magnetic switch coil (layer short-circuit) Failure of returning action in ignition switch Replace magnetic switch. Replace magnetic switch. Replace,UNIT REPAIR OVERHAUL yo 1. Dive nousing assembly 2 Blank 3. Snapeng 4 Pinion ston rng ABH 5. Over running clutch assembly. Apply grease A 96000-25010 inside and outade of eine. ABH 6 Amature ‘Aoply grease A 99000-25010 to jit of tive housing bush, over-canning catch land armature shaft bush ABH 7. Pinion ave lever ‘Apply grease A 99000-25010 to jit of ‘magnetic such and over running euch. 2 Seal 9. Boot 10, Magnetic switch 11, Rear housing 12. Brush spring 12. Brush holder Apply grease A 96000-25010 inside and outs, 48 Bash AT Yoke assembly 18. Housing batt €} Donotreuse CRANKING SYSTEM 66-566-6 _CRANKING SYSTEM. DISMOUNTING AND REMOUNTING 1) Disconnect negative cable at battery. 2) Remove A/C compressor (if equipped), refer to SECTION 1B, 3) Disconnect magnetic switch lead wire and battery cable from starting motor terminals. 4) Remove 2 mounting bolts. 5) Remove starting motor. 6) To remount, reverse above procedure. DISASSEMBLY 1) Remove nut (2) and disconnect lead wire (1) from magnetic ‘switch (3). 2) Remove 2 nuts (4) and then take out magnetic switch by pulling Up its rear portion so as to inside hook is disconnected from drive lever. NOTE: Do not disassemble magnetic switch. Replace it as assom- bly, when required. 3) Remove housing bolts (through bolts) and then pull out commu tator end housing. 4) Remove insulator, brush springs (1) and then brush holder (2) 5) Remove yoke, armature (1) and drive lever (2) from drive hous- a A ing (3). 6) Draw pinion stop ring (3) toward over-running clutch (4) side and remove snap ring (2) by using snap ring pliers assisted with screwdriver, then pull out pinion stop ring and over-running clutch from armature (1), Special Tool (A) : 09900-06107CRANKING SYSTEM_6G-7 REASSEMBLY 1) Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary. 2) Before installing over-running clutch (2) to armature (1), apply grease as shown in figure and then fasten stop ring (3) with snap ring (4). “A” : Grease 99000-25010 NOTE: Use new snap ring on shaft for installation. Do not reuse snap ring. 3) Apply grease to drive lever (2) and combine it with armature (1). Then assemble them with drive housing (3). “A” : Grease 99000-25010 4) Install yoke and brush holder (3), then set 4 brushes (1) with their springs (2). Install insulator. NOTE: © When installing brushes, make sure that brushes and commutator have been degreased thoroughly. © Check to confirm that brush parts do not have unneces- sary contacts with others. 5) Install rear housing applied with grease in its bush inside. Grease 99000-25010 6) Replace magnetic switch (1) or its boot (2) with new one, if re- quired, then apply grease to plunger (3). “A” : Grease 99000-2501066-8 _CRANKING SYSTEM 7) Hook magnetic switch plunger (3) with drive lever and then fas- ten magnetic switch assembly (1) with nuts (4) 8) Connect lead wire (5) as it was and then check magnetic switch for operation. NOTE: © Before installing nuts, make sure that plunger hook is connected with drive lever without fail. © Face boot (2) breather down. Upon completion of assembly, carry out PERFORMANCE TEST. INSPECTION 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). Ifno continuity exists, coil is open and should be replaced.CRANKING SYSTEM 66-9 © Hold-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S' terminal (1) and coil case. If no continuity exists, coil is open and should be re- placed BRUSH Measure length of brushes and replace them as necessary. Brush length Limit : 6.0 mm (0.236 in.) BRUSH HOLDER Check brush springs for rust or breakage. Also check brush holder for rust and insulation. Replace it as assembly, if required. ARMATURE © Ground Test Between commutator segment and armature core should be in- sulated. Use ohmmeter for inspection. © 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.66-10_CRANKING SYSTEM 4. Mica nsulatr 2. Commutator segment A Free cation © Check commutator for run-out with armature (1) supported on \V-blocks (2). Correct it by using lathe, if required, ‘Commutator out of round Limit (maximum value): 0.4 mm (0.015 in.) ‘© Check for wear and replace armature if diameter is below limit. Commutator outside diameter Limit (minimum value): 27 mm (1.063 in.) © Correct and clean surface by using #400 emery cloth Also check mica depth and correct it as required. Commutator insulator depth “a” Limit (minimum value): 0.2 mm (0.008 in.) YOKE Cheek field coil for continuity. There should be continuity between following terminals. © Between A terminals. © Between B terminals. © Between B terminal and C (bare metal part of yoke body). OVER-RUNNING CLUTCH Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and ro- tates smoothly in reverse direction. Replace if necessary.4. Terminal S CRANKING SYSTEM PERFORMANCE TEST CAUTION: Each test must be performed within 3 — 5 seconds to avoid coil from burning. PULL-IN TEST Connect test leads as shown in figure and check that pinion (over- running clutch) move outward. If it does not, replace magnetic switch. NOTE: Before testing, disconnect field coil lead wire (3) from ‘M' ter- minal (2). HOLD-IN TEST While connected as the above with pinion out, disconnect negative lead from “M' terminal (1) and check that pinion remains out. Ifnot, replace magnetic switch.CRANKING SYSTEM PINION (PLUNGER) RETURN TEST As anext step to the above, disconnect negative lead and check to make sure that pinion returns inward quickly. NO-LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out. Also check that ammeter: indicates specified current. Specified Current: 50A at 11.5VCRANKING SYSTEM 66-13 SPECIFICATIONS Voltage 12 volts Output 0.6 kW Rating 30 seconds Clockwise as viewed from pinion side (F8D engine) Direction of rotat rection of rotation Counterclockwise as viewed from pinion side (F8B engine) Brush length 10.0 mm (0.394 in.) Number of pinion teeth 8 Performance Condition | Guarantee 50 A maximum, No load characteristic | 11.5V # feag onaracienistic 6,000 rpm minimum Around at | Load characteristic | 9Y 2.75 Nem minimum we eey) 150A 4,900 rpm minimum Locked rotor current | 5.5V 400 A maximum 5.89 Nom (0.5 kg-m, 4.6 Ib-ft) minimum Magnetic switch operating voltage _| 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT USE ‘Armature shaft Over-running clutch. ° SUZUKI SUPER GREASE A . ‘© Commutator end cap. . . ‘ihlam grease (99000-25010) Drive lever. Bush, SPECIAL TOOL 09900-06107 Snap ring pliers (Opening type)