1998-2003 Suzuki Alto 4 Door Cranking System User Manual
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Cranking System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

6G
CRANKING SYSTEM 6G-1
SECTION 6G
CRANKING SYSTEM
CONTENTS
GENERAL DESCRIPTION 6G-2. . . . . . . . . . . . . . .
Cranking Circuit 6G-2. . . . . . . . . . . . . . . . . . . . . .
Starting Motor Circuit 6G-2. . . . . . . . . . . . . . . . . .
DIAGNOSIS 6G-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL 6G-5. . . . . . . . . . . . . . .
Dismounting and Remounting 6G-6. . . . . . . . . .
Disassembly 6G-6. . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 6G-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6G-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plunger 6G-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic switch 6G-8. . . . . . . . . . . . . . . . . . . .
Brush 6G-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush holder 6G- 9. . . . . . . . . . . . . . . . . . . . . .
Armature 6G- 9. . . . . . . . . . . . . . . . . . . . . . . . .
Yoke 6G-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Over-running clutch 6G-10. . . . . . . . . . . . . . . .
Performance Test 6G-11. . . . . . . . . . . . . . . . . . . .
Pull-in test 6G-11. . . . . . . . . . . . . . . . . . . . . . . .
Hold-in test 6G-11. . . . . . . . . . . . . . . . . . . . . . .
Pinion return test 6G-12. . . . . . . . . . . . . . . . . .
No-load performance test 6G-12. . . . . . . . . . .
SPECIFICATIONS 6G-13. . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL 6G-13. . . . . . .
SPECIAL TOOL 6G-13. . . . . . . . . . . . . . . . . . . . . . .
6G-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
D The magnetic switch coils are magnetized when the ignition switch is closed.
D 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.
D 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.
CRANKING SYSTEM 6G-3
DIAGNOSIS
Possible symptoms due to starting system trouble would be as follows:
D Starting motor does not run (or runs slowly)
D Starting motor runs but fails to crank engine
D 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
D Battery run down
D Battery voltage too low due to battery deterioration
D Poor contact in battery terminal connection
D Loose grounding cable connection
D Fuse set loose or blown off
D Poor contacting action of ignition switch and magnetic
switch
D Lead wire coupler loose in place
D Open-circuit between ignition switch and magnetic
switch
D Open-circuit in pull-in coil
D Brushes are seating poorly or worn down
D Poor sliding of plunger and/or pinion
Recharge battery.
Replace battery.
Retighten or replace.
Retighten.
Tighten or replace.
Replace.
Retighten.
Repair.
Replace magnetic switch.
Repair or replace.
Repair.
Operating sound of magnetic switch heard
D Battery run down
D Battery voltage too low due to battery deterioration
D Loose battery cable connections
D Burnt main contact point, or poor contacting action of
magnetic switch
D Brushes are seating poorly or worn down
D Weakened brush spring
D Burnt commutator
D Poor grounding of field coil
D Layer short-circuit of armature
D Crankshaft rotation obstructed
Recharge battery.
Replace battery.
Retighten.
Replace magnetic switch.
Repair or replace.
Replace.
Replace armature.
Repair.
Replace.
Repair.
6G-4 CRANKING SYSTEM
Condition Possible Cause Correction
Starting motor
running but too
slow (small torque)
If battery and wiring are satisfactory, inspect
starting motor
D Insufficient contact of magnetic switch main contacts
D Layer short-circuit of armature
D Disconnected, burnt or worn commutator
D Poor grounding of field coil
D Worn brushes
D Weakened brush springs
D Burnt 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
D Worn pinion tip
D Poor sliding of over-running clutch
D Over-running clutch slipping
D Worn teeth of pinion gear or flywheel
Replace over-running clutch.
Repair.
Replace over-running clutch.
Replace pinion or flywheel.
Noise D Abnormally worn bush
D Worn pinion or worn teeth of pinion gear
D Poor sliding of pinion (failure in return movement)
D Lack of oil in each part
Replace bush.
Replace pinion or flywheel.
Repair or replace.
Lubricate.
Starting motor
does not stop run-
ning
D Fused contact points of magnetic switch
D Short-circuit between turns of magnetic switch coil
(layer short-circuit)
D Failure of returning action in ignition switch
Replace magnetic switch.
Replace magnetic switch.
Replace.
CRANKING SYSTEM 6G-5
UNIT REPAIR OVERHAUL
1. Drive housing assembly
2. Blank
3. Snap ring
4. Pinion stop ring
5. Over-running clutch assembly:
Apply grease A 99000-25010 to inside
and outside of spline.
6. Armature:
Apply grease A 99000-25010 to joint of
drive housing bush, over-running clutch
and armature shaft bush.
7. Pinion drive lever:
Apply grease A 99000-25010 to joint of
magnetic switch and over-running clutch.
8. Seal
9. Boot
10. Magnetic switch
11. Rear housing
12. Brush spring
13. Brush holder
14. Insulator
15. Bush:
Apply grease A 99000-25010 to inside
and outside.
16. Brush
17. Yoke assembly
18. Housing bolt
: Do not reuse
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 assem-
bly, when required.
A: Pull up to disconnect hook
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-
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
6G-6 CRANKING SYSTEM
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:
D When installing brushes, make sure that brushes and
commutator have been degreased thoroughly.
D 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
CRANKING SYSTEM 6G-7
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:
D Before installing nuts, make sure that plunger hook is
connected with drive lever without fail.
D 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.
D Pull-In Coil Open Circuit Test
Check for continuity across magnetic switch ‘S’ terminal (1) and
‘M’ terminal (2). If no continuity exists, coil is open and should be
replaced.
6G-8 CRANKING SYSTEM
D 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
D Ground Test
Between commutator segment and armature core should be in-
sulated. Use ohmmeter for inspection.
D 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.
CRANKING SYSTEM 6G-9
D 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.)
D Check for wear and replace armature if diameter is below limit.
Commutator outside diameter
Limit (minimum value): 27 mm (1.063 in.)
D 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.)
1. Mica insulator
2. Commutator segment
YOKE
Check field coil for continuity. There should be continuity between
following terminals.
D Between A terminals.
D Between B terminals.
D 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.
A: Free rotation
6G-10 CRANKING SYSTEM
PERFORMANCE TEST
CAUTION:
Each test must be performed within 3 – 5 seconds to
avoid coil from burning.
1. Terminal ‘S’
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. If not,
replace magnetic switch.
CRANKING SYSTEM 6G-11
PINION (PLUNGER) RETURN TEST
As a next 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
6G-12 CRANKING SYSTEM
SPECIAL TOOL
09900-06107
Snap ring pliers
(Opening type)
CRANKING SYSTEM 6G-13
SPECIFICATIONS
Voltage
12 volts
Output 0.6 kW
Rating 30 seconds
Direction of rotation
Clockwise as viewed from pinion side (F8D engine)
Counterclockwise as viewed from pinion side (F8B engine)
Brush length 10.0 mm (0.394 in.)
Number of pinion teeth 8
Performance Condition Guarantee
No load characteristic 11.5 V
50 A maximum
6,000 rpm minimum
Around at
20 C (68 F)
Load characteristic
9 V
150 A
2.75 N·m minimum
1,900 rpm minimum
20
C
(68
F)
Locked rotor current 5.5 V
400 A maximum
5.89 N·m (0.5 kg-m, 4.6 Ib-ft) minimum
Magnetic switch operating voltage 8 volts maximum
REQUIRED SERVICE MATERIAL
MATERIAL
RECOMMENDED
SUZUKI PRODUCT
USE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)
D Armature shaft.
D Over-running clutch.
D Commutator end cap.
D Drive lever.
D Bush.

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