Suzuki Grand Vitara JB416 / JB420. Manual - part 135

1I-8 Starting System: 

Brush Spring
Inspect brush springs for wear, damage or other 
abnormal conditions. Replace if necessary.

Brush spring tension
Standard: 1.8 kg (3.97 lb)
Limit: 0.3 kg (0.67 lb)

Brush Holder
• 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 (positive 

side) and grounded brush (negative side). If continuity 
exists, brush holder is grounded due to defective 
insulation and should be replaced.

Armature
• Inspect commutator for dirt or burn. Correct with 

sandpaper or lathe, if necessary.

• Check commutator for uneven wear with armature (1) 

supported on V-blocks (2). If deflection of dial gauge 
(4) pointer exceeds limit, repair or replace.

NOTE
The following specification presupposes that 
armature is free from bend. Bent armature 
must be replaced.

 

Commutator out of round
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.4 mm (0.016 in.)

• Inspect commutator for wear. If diameter is below 

limit, replace armature.

Commutator outside diameter
Standard: 29.4 mm (1.16 in.)
Limit: 28.8 mm (1.13 in.)

• Inspect commutator for insulator depth. Correct or 

replace if below limit.

Commutator insulator depth “a”
Standard: 0.4 – 0.6 mm (0.016 – 0.024 in.)
Limit: 0.2 mm (0.008 in.)

I4RS0A190004-01

IYSQ01190034-01

3. Magnetic stand

[A]: Correct

1. Commutator segment

[B]: Incorrect

2. Insulator

IYSQ01190035-01

IYSQ01190036-01

I5JB0A190003-01

Starting System:  1I-9

Ground test
Check the commutator and armature core. If there is 
continuity, armature is grounded and must be replaced.

Open circuit test
Check for continuity between segments. If there is no 
continuity at any test point, there is an open circuit and 
the armature must be replaced.

Gears
Inspect internal gear and the planetary gears for wear, 
damage or other abnormal conditions. Replace if 
necessary.

Pinion and Over-Running Clutch
• Inspect pinion for wear, damage or other abnormal 

conditions. Check that clutch locks up when turned in 
direction of drive and rotates smoothly in reverse 
direction. Replace if necessary.

• Inspect spline teeth for wear or damage. Replace if 

necessary. Inspect pinion for smooth movement.

Front Housing Bush
Inspect bush for wear or damage. Replace if necessary.

IYSQ01190038-01

IYSQ01190039-01

IYSQ01190040-01

IYSQ01190041-01

IYSQ01190042-01

IYSQ01190043-01

1I-10 Starting System: 

Specifications

Starting Motor Specifications

S5JB0A1907001

1.2 kW Type [1.4 kW Type]

Tightening Torque Specifications

S5JB0A1907002

NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0A1908001

NOTE
Required service material is also described in the following.
“Starting Motor Components”

 

Voltage

12 volts

Output

1.2 kW [1.4 kW]

Rating

30 seconds

Direction of rotation

Clockwise as viewed from pinion side

Brush length

Standard: 12.3 mm (0.48 in.)

Limit: 5.5 mm (0.22 in.)

Number of pinion teeth

8

Performance

Condition

Guarantee

Around 
at 20 

°C (68 °F)

No load characteristic

11.0 V

90 A maximum
2370 r/min minimum [2000 r/min minimum]

Load characteristic

7.5 V

300 A

10.65 N

⋅m (1.065 kgf-m, 7.70 lb-ft) minimum

[11.0 N

⋅m (1.1 kgf-m, 7.95 lb-ft) minimum]

840 r/min minimum

Locked characteristic

4.0 V

[3.0 V]

780 A maximum
[860 A maximum]
20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) minimum

Magnetic switch operating voltage 8 volts maximum

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Starting motor battery cable nut

11

1.1 

8.0

)

Charging System:  1J-1

Engine

Charging System

General Description

Battery Description

S5JB0A1A01001

The battery has three major functions in the electrical system.
• It is a source of electrical energy for cranking the engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.

Carrier and Hold-Down
The battery carrier should be in good condition so that it will support the battery securely and keep it level.
Before installing the battery, the battery carrier and hold-down clamp should be clean and free from corrosion and 
make certain there are no parts in carrier.
To prevent the battery from shaking in its carrier, the hold-down bolts should be tight enough but not over-tightened.

Electrolyte Freezing
The freezing point of electrolyte depends on its specific gravity. Since freezing may ruin a battery, it should be 
protected against freezing by keeping it in a fully charged condition. If a battery is frozen accidentally, it should not be 
charged until it is warmed.

Sulfation
If the battery is allowed to stand for a long period in discharged condition, the lead sulfate becomes converted into a 
hard, crystalline substance, which will not easily turn back to the active material again during the subsequent 
recharging. “Sulfation” means the result as well as the process of that reaction.
Such a battery can be revived by very slow charging and may be restored to usable condition but its capacity is lower 
than before.

Built-in Indicator (if equipped)
The battery has a built-in temperature compensated indicator (1) in the top of the battery. This indicator is to be used 
with the following diagnostic procedure. 
When checking the indicator, make sure that the battery has a clean top. A light may be needed in some poorly-lit 
areas.
Three types of indication available under normal operation are as follows.

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