Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Starter

Print

TESTING



See Figures 1, 2, 3 and 4


WARNING
During the following test, the starter motor must not be energized for longer than 5 seconds, otherwise you run the risk of burning out the starter motor coil.

  1. Remove the starter motor from the vehicle.
  2.  
  3. Detach the field coil lead from terminal M on the starter motor.
  4.  
  5. Using jumper wires, connect a 12 volt battery to the starter motor so that the negative battery terminal is attached to the starter motor housing and to solenoid terminal M , and that the positive battery terminal is connected to starter motor solenoid terminal S . The starter motor plunger should move outward; if it does not, replace the solenoid with a new one.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: To test the solenoid plunger, first detach the field coil lead from alternator terminal M, then attach a 12 volt battery to the starter motor as shown ...



Click image to see an enlarged view

Fig. Fig. 2: ... then detach the negative jumper wire from terminal M. The plunger should remain extended



Click image to see an enlarged view

Fig. Fig. 3: Detach the other negative lead from the starter motor housing. The solenoid plunger should now retract to its normal resting position



Click image to see an enlarged view

Fig. Fig. 4: Use an ammeter to measure the amount of current draw the starter motor uses

  1. Detach the negative battery jumper wire from terminal M on the starter motor solenoid, and check the plunger for movement. The plunger should remain extended; if the plunger returns to its resting position, replace the solenoid with a new one.
  2.  
  3. While observing the solenoid plunger, detach the negative battery lead from the starter motor housing. The plunger should return to its normal resting position; if it does not, replace the solenoid with a new one.
  4.  
  5. Reattach the 12 volt battery and install an ammeter to the starter motor as shown in the accompanying illustration. The starter motor should rotate smoothly and steadily with the pinion gear moving out, and the ammeter should display less than 60 amps at 11.5 volts (Samurai models), or 90 amps at 11 volts (Sidekick, Tracker, X-90 and Sidekick Sport models). If the ammeter does not display the specified values, or if the starter motor does not operate smoothly and steadily, replace the starter motor with a new one.
  6.  

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable.
  2.  
  3. If necessary for added under-vehicle clearance, apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. From beneath the vehicle, label and detach all wiring from the starter motor solenoid terminals.
  6.  
  7. Remove one of the two starter motor mounting bolts and loosen the other bolt until it can be turned by hand, then support the starter motor with one hand while removing the last starter motor mounting bolt.
  8.  
  9. Lower the starter motor down and away from the engine and transmission.
  10.  

To install:
  1. Hold the starter motor in position and install the two mounting bolts. Tighten the two bolts securely.
  2.  
  3. Reattach all applicable wiring to the starter motor solenoid. Ensure that the wiring terminals and connectors are clean and free of corrosion.
  4.  
  5. If necessary, lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  

SOLENOID REPLACEMENT



See Figures 5, 6 and 7

Prior to removing the solenoid from the starter motor unit, matchmark the solenoid-to-starter motor housing position, as shown in the accompanying illustration.

  1. Remove the starter motor from the vehicle.
  2.  
  3. Detach the solenoid-to-starter motor wire from the solenoid terminal.
  4.  

Do not disassemble the solenoid; if the solenoid is defective, replace the entire unit with a new one.

  1. Remove the two attaching screws, then slide the solenoid out of the starter motor housing flange.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Before removing the starter motor solenoid, matchmark the solenoid-to-starter motor housing relationship



Click image to see an enlarged view

Fig. Fig. 6: Disconnect the field coil lead from the solenoid by loosening the retaining nut ...



Click image to see an enlarged view

Fig. Fig. 7: ... then remove the two attaching screws and separate the solenoid from the motor housing

To install:
  1. Inspect the solenoid plunger joint for wear or other damage. Replace it, if damage is evident.
  2.  
  3. Apply Suzuki Super Grease A (99000-25010) or equivalent, to the solenoid plunger and to the tip of the lever arm (inside the starter motor-to-solenoid housing hole).
  4.  
  5. Insert the solenoid into the starter motor housing, ensuring that the matchmarks made during removal are aligned.
  6.  
  7. Install and tighten the two attaching screws securely.
  8.  
  9. Attach the starter motor-to-solenoid wire to the solenoid terminal.
  10.  
  11. While the starter motor is removed form the vehicle, perform the testing procedure to ensure that the new solenoid functions properly.
  12.  
  13. Install the starter motor.
  14.  

 
label.common.footer.alt.autozoneLogo