38100-87L00 Suzuki MOTOR ASSY, PTT

Battery
Every 10,000 miles (160 000 km) check the electrolyte level of each cell and the general condition of the battery. Maintain the electrolyte level to the base of each vent well. The make-up water must be one of the following (in order of preference): 1. Distilled water.2. Odorless, tasteless drinking water.3. Iron free water.4. Any available water.
Never add acid or electrolyte.
CLEANING BATTERY: Mix a weak solution of baking soda and water. Apply the solution with a soft bristle brush. Be careful not to get cleaning solution into the battery.
CLEANING BATTERY TERMINALSThoroughly rinse the battery and battery tray with clean water. Apply grease to the battery cable clamps and terminals and to all threads. TESTING THE ELECTROLYTE SOLUTION: The general condition of a battery can be determined by measuring the specific gravity of the electrolyte solution and adjusting the reading to 80°F (27°C). If the electrolyte level is too low to allow taking a hydrometer reading, add make-up water to the correct level and then charge the battery 2 to 4 hours before taking a reading. 1. Insert the hydrometer into a cell. Fill the hydrometer barrel while holding it vertically. The float must not drag on the wall of the barrel.2. Read the hydrometer: 1.250 or above - fully charged battery cell1.250-1.225 - full to half charged battery cell1.225-1.150 - half to low charged battery cellBelow 1.150 - dead cell1.000 - water3. Test each cell in the same manner.4. If there is more than .050 (50 gravity points) variation between the highest and lowest reading, the battery should be replaced.5. Adjust the readings to 80°F (27°C). a. For every 10°F (5.5°C) the electrolyte temperature is above 80°F (27°C), add .004 (4 gravity points) to the specific gravity readings.b. For every 10°F (5.5°C) the electrolyte temperature is below 80°F (27°C), subtract .004 (4 gravity points) from the specific gravity reading.The corrected reading is of most importance during cold weather when the hydrometer reading is always corrected to a lower specific gravity reading. A low reading signifies the battery has less available power to crank the engine and that booster batteries may be required.
TESTING ELECTROLYTE SOLUTION VOLTAGE TEST (AFTER LOAD): A load test should be made on a battery that discharges very rapidly when in use. To do this apply a resistance of three times the ampere/hour rating of the battery across the battery main terminals. Allow the resistance to discharge the battery for 15 seconds and immediately test the battery voltage. A 6 volt battery in good condition will test 4.5 volts; a 12 volt battery in good condition will test 9 volts and a 24 volt battery will test 18 volts.Starting System
Use a D.C. voltmeter to locate starting system components which do not function.Turn the key switch ON. Turn the HEAT-START switch to the START position. Starting motor solenoid operation is audible as the starter motor pinion engages with the ring gear on the engine flywheel. The solenoid operation should also close the electric circuit to the starting motor. Attach one voltmeter lead to the solenoid terminal that is connected to the starting motor. Ground the other lead. Turn the HEAT-START switch to START and observe the voltmeter. A battery voltage reading indicates the malfunction is in the starting motor. It must be removed for further testing. No voltmeter reading indicates that the solenoid contacts do not close. The solenoid must be repaired or the starter pinion clearance should be adjusted to .36 in. (9,14 mm). See topic PINION CLEARANCE ADJUSTMENT. A starting motor solenoid that will not operate may not be receiving battery current. Attach one lead of the voltmeter to the solenoid battery cable connection. Ground the other lead. No voltmeter reading indicates a faulty circuit from the battery. A voltmeter reading indicates further testing is necessary. Continue the test by attaching one voltmeter lead to the starting motor solenoid small wire terminal and the other lead to ground. Observe the voltmeter and turn the HEAT-START switch to START. A voltmeter reading indicates that the malfunction is in the solenoid. No voltmeter reading indicates that either the series-parallel switch is the fault or the HEAT-START switch does not close when turned to the START position. Attach one lead of the voltmeter to the HEAT-START switch battery wire terminal and ground the other lead. A voltmeter reading indicates a defective switch. No voltmeter reading indicates further testing of the series-parallel switch is necessary. A starting motor that operates too slow can be overloaded by excessive mechanical friction within the engine being started. Slow starting motor operation can also be caused by shorts, loose connections and/or excessive dirt within the motor. PINION CLEARANCE ADJUSTMENT: Whenever the solenoid is installed, the pinion clearance should be adjusted. The adjustment should be made with the starting motor removed.Bench test and adjust the pinion clearance at installation of solenoid as follows: 1. Install the solenoid without connector from the MOTOR terminal on solenoid to the motor.2. Connect a battery, of the same voltage as the solenoid, to the terminal marked SW.3. Connect the other side of battery to ground terminal or to solenoid frame.
ADJUSTING PINION CLEARANCE4. MOMENTARILY flash a jumper wire from the solenoid terminal marked MOTOR to the frame or ground terminal. The pinion will shift into cranking position and will remain there until the battery is disconnected.5. Push pinion towards commutator end to eliminate free movement.6. Pinion clearance should be .36 in. (9,14 mm).7. Adjust clearance by removing plug and turning shaft nut.General Reconditioning
Approximately every 200,000 miles, the starter should be removed so that it may be completely disassembled, washed and have all parts replaced that show evidence of being unsatisfactory for reason of wear. Do not use a degreaser or high temperature cleaning method when cleaning parts of the starter.No periodic service is indicated for the electric starter brushes between general reconditioning periods. The brushes should only be inspected after removal of the starter from the engine and removal of the commutator end bearing frame. The electric starter commutator