09138-06037 Suzuki BOLT

Circuit Diagram-System with ETS Solenoid Switch and Alternator Having Integral Electronic Regulator2. Starter Motor
2.1 Disassembly
1 Pinion set2 Solenoid switch3 Rear bracket4 Brush holder5 Yoke6 Armature7 Ball bearing8 Ball9 Seal set10 Reduction gears11 Lever set12 Washer set13 Gear shaft14 Internal gear15 Overrunning clutch16 Front bracket
The pinion must be removed before removal or replacement of the following parts:1 Front bracket2 Reduction gears3 Overrunning clutch
(1) Removing PinionThe pinion can be removed when it is held in the pushed-out position during energization of the solenoid switch. Disconnect the M-terminal connector and make a circuit that connects the starter motor and the battery as shown in the drawing. Close switches S1 and S2 to make the pinion come out and rotate. Then, open switch S2. The pinion will stop rotating but will stay in the pushed-out position. Apply a pipe-shaped implement to the pinion stopper and lightly tap it with a hammer to remove the pinion. If the pinion returns to the retracted position before disengagement of the stopper while the tool is being tapped, repeat the procedure from the beginning. (2) BallThe ball at the end of the armature acts as a bearing for movement of the armature in the thrust direction. When the armature is removed, the ball may stick to the grease on it. Be careful not to lose the ball.2.2 Inspection(1) Armature(a) Coil Short Circuit TestPlace the armature on a growler test. Hold an iron rod parallel with the armature and slowly rotate the armature by hand. If the iron rod vibrates or is pulled toward the armature, the armature has a short-circuited coil and must be replaced. (b) Coil Ground TestCheck whether continuity exists between the commutator and shaft (or core). If continuity exists, the coil is grounded and the armature must be replaced. (c) Commutator Inspection1) Measure the commutator's runout using a dial gauge. If the measurement exceeds the specified limit, rectify the problem, making sure that the outside diameter stays within specification. If the surface is rough or has stepped wear, rectify the problem with emery paper (#300-500).
Unit: mm (in.) 2) Measure the commutator's outside diameter. If the measurement is out of specification, replace the armature.
Unit: mm (in.) 3) Measure the molding undercut depth between segments. If the depth is smaller than the limit, cut the molding to a depth of 0.4-0.6 mm (0.016-0.024 in.).
Unit: mm (in.) (2) Field Coil(a) Coil Open Circuit TestCheck whether continuity exists between the terminal lead and each brush. If continuity does not exist, the field coil has an open circuit and the yoke assembly must be replaced. (b) Coil Ground TestCheck whether continuity exists between the yoke and each brush. If continuity exists, the coil is grounded and must be checked for defective insulation. If repair is impossible, replace the yoke assembly. (3) Brushes and Brush Holders(a) Brush WearMeasure the length of the brush. If the measurement is smaller than the limit, replace the brush. If the brush is worn unevenly or has a rough contact surface, rectify the problem with fine emery paper (#300-500).
Unit: mm (in.) (b) Brush Spring ForceWith a new brush installed, pull the brush spring with a spring balance and read the load at the point where the spring leaves the brush. Replace the spring if its force is lower than the limit.
N {kgf} (lbf) (c) Brush Holder Insulation TestCheck whether continuity exists between the (+) brush holder and the (-) brush holder plate. If continuity exists, replace the brush holder assembly. (4) Overrunning ClutchMake sure the pinion shaft rotates smoothly when turned clockwise (in the drive direction) and locks when turned counterclockwise. If the pinion shaft's operation is defective, replace the overrunning clutch. (5) Gear Shaft Thrust GapAdjustment of the gear shaft's thrust gap is not necessary.(6) Armature Thrust GapAdjustment of the armature's thrust gap is not necessary.2.3 Assembly Assembly sequence 2.4 Inspection and Testing after AssemblyAfter assembling the starter, perform the following inspections and tests:(1) Inspection and Adjustment of Pinion Gap(a) Connect the assembled starter to the battery as shown in the drawing. The pinion will come out and rotate slowly. Then, remove the M-terminal connector to stop the motor.(b) Lightly push the pinion shaft toward the armature and measure the amount of axial movement, which corresponds to the pinion gap.(c) If the pinion gap is not within the 0.5-2.0 mm (0.02-0.08 in.) range, adjust it by increasing or decreasing the number of seals in the solenoid switch. (Increasing the number of seals reduces the pinion gap.) It may be necessary to replace the lever to obtain the correct pinion gap.
Unit: mm (in.) To prevent the solenoid switch coil from overheating, do not energize the solenoid switch for longer than 10 seconds.(2) No-Load TestWhen the pinion gap has been correctly adjusted, connect an ammeter and a voltmeter between the starter motor and battery as shown in the drawing, then check the starter's no-load characteristics.
Use the thickest wires possible, and tighten each terminal firmly.
(3) Solenoid SwitchPerform the following continuity tests. If the solenoid switch fails either test, replace it.(a) Test for Coil Open CircuitContinuity should exist between the S- and M-terminals and between the S-terminal and ground (case).(b) Test for Fused ContactsContinuity should not exist between the B- and M-terminals. 3. Alternator
With the charging system, excessive charging and discharging can be caused by various problems as listed below. Some of these problems can be checked with the alternator fitted on the machine, but others require the alternator's removal before inspection and repair operations can be performed. The alternator should be removed only when absolutely necessary. 3.1 On-Machine Inspection(1) Handling PrecautionsTo avoid damaging the alternator and/or related electrical components, be sure to observe the following handling precautions:(a) Never reverse the battery connections. Connect only the ground cable to the battery's (-) terminal.(b) N