Suzuki Grand Vitara JB419. Manual - part 69

Starting System:  1I-5

Starting Motor Dismounting and Remounting

S5JB0B1906001

WARNING

!

 

To avoid danger of being burned, do not 
service exhaust system while it is still hot. 
Service should be performed after system 
cools down.

 

1) Disconnect negative (–) cable at battery.
2) Remove air cleaner outlet hose.
3) Remove catalytic converter referring to “Exhaust 

System Components in Section 1K”.

4) Disconnect magnetic switch lead wire (3) and battery 

cable (4) from starting motor terminals.

5) Remove 3 starting motor mount bolts (2).
6) Remove starting motor (1).
7) To install, reverse the above procedure.

Starting Motor Disassembly and Assembly

S5JB0B1906002

Disassembly

NOTE
Do not clamp yoke in a vise or strike it with a 
hammer during repair operations.

 

1) Disconnect lead wire from terminal “M” (1).
2) Loosen through bolts (2).

3) Loosen magnetic switch screw (1) and then remove 

front housing (2).

4) Put match marks (1) on magnetic switch (2) and 

planetary carrier shaft assembly (3) to install the 
magnetic switch correctly in position.

5) Loosen magnetic switch inner screw (4) and then 

remove magnetic switch (2) and spring (5).

CAUTION

!

 

Don’t disassemble this switch. If defective, 
replace as a complete assembly.

 

6) Remove pin (1) and then remove from lever (2) and 

then plunger / lever assembly.

3. Magnetic switch bolt

7. Spring

11. Nut

15. Snap ring

4. Through bolt

8. Magnetic switch

12. Washer

: Do not reuse.

: 55 N

⋅m (5.5 kg-m, 40.0 lb-ft)

: 8  N

⋅m (8.0 kg-m, 6.0lb-ft)

(a)

(a)

2,

2,

1

(b)

3

4

I5JB0B190007-01

1

2

I5JB0B190008-01

1

2

I5JB0B190009-01

1

2

3

4

4

5

I5JB0B190010-01

1

2

I5JB0B190011-01

1I-6 Starting System: 

7) Remove planetary carrier shaft assembly (1) from 

yoke (2).

CAUTION

!

 

Don’t disassemble motor. If defective, 
replace as a complete assembly.

 

8) Loosen pinion stop ring (2) fixed by snap ring (1).

9) Remove snap ring and then pull out pinion stop ring 

(1) and over-running clutch (2) from planetary carrier 
shaft (3).

Assembly

1) Install over-running clutch (1) to planetary carrier 

shaft (3), using care for installing direction of pinion 
stop ring (2).

2) Install planetary carrier shaft assembly (1) to yoke 

(2).

3) Install lever (2) to planetary carrier shaft assembly 

(3) and then insert pin (1).

1

2

I5JB0B190012-01

I5JB0B190013-01

1

2

3

I5JB0B190014-01

I5JB0B190015-01

1

2

I5JB0B190012-01

1

2

3

I5JB0B190016-01

Starting System:  1I-7

4) Install spring (5) and magnetic switch (2) to plunger 

and then tighten magnetic switch inner screw (4).

CAUTION

!

 

With marks (1) on magnetic switch (2) and 
planetary carrier shaft assembly (3) marked 
before remove aligned to each other.

 

5) Install front housing (2) and then tighten magnetic 

switch screw (1).

6) Install through bolts (2) and then tighten through 

bolts.

7) Connect lead wire to terminal “M” (1).

Starting Motor Inspection

S5JB0B1906004

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.

1

2

3

4

4

5

I5JB0B190010-01

1

2

I5JB0B190009-01

1

2

I5JB0B190017-02

I5JB0B190018-01

I5JB0B190019-01

I5JB0B190020-02

1I-8 Starting System: 

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.

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.

Specifications

Starting Motor Specifications

S5JB0B1907001

Tightening Torque Specifications

S5JB0B1907002

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

 

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

I5JB0B190021-02

I5JB0B190022-01

I5JB0B190023-01

Voltage

12 volts

Output

2.2kW

Rating

30 seconds

Direction of rotation

Clockwise as viewed from pinion side

Number of pinion teeth

11

Performance

Condition

Guarantee

Around 
at 20 

°C (68 °F)

No load characteristic

11.0 V

90 A maximum
2400 rpm minimum

Load characteristic

7.5 V

300 A

10.8 N

⋅m (1.1 kg-m, 7.8 lb-ft) minimum

870 rpm minimum

Locked characteristic

3.0 V

840 A maximum
19.8 N

⋅m (2.0 kg-m, 14.3 lb-ft) minimum

Magnetic switch operating voltage

8 volts maximum