Get Cranking System -> Unit Repair Overhaul Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

Cranking System -> Unit Repair Overhaul for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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