Starting Motor Operation Check

CAUTION:

When connecting cables to battery for the operation check, give enough care not to make an accidental short.
Each test must be performed within 3 to 5 seconds to avoid burning of coil.

Perform PULL-IN TEST as follows.
1. Disconnect lead wire (3) from terminal "M" (2).
2. Connect battery to magnetic switch as shown in figure.
3. Check that plunger and pinion move outward.
  If plunger and pinion do not move, replace magnetic switch.
  
  Fig 1: Connecting Battery To Magnetic Switch
  Courtesy of SUZUKI OF AMERICA CORP.
Perform HOLD-IN TEST as follows.
1. From the state of step 1) with plunger and pinion in "out" position, disconnect negative (-) lead from terminal "M".
2. Check that plunger and pinion remain in "out" position.
  If plunger and pinion return inward, replace magnetic switch.
  
  Fig 2: Disconnecting Negative (-) Lead From Terminal M
  Courtesy of SUZUKI OF AMERICA CORP.
Perform plunger and pinion return test as follows.
1. From the state of step 2) with plunger and pinion in "out" position, disconnect negative (-) lead from starting motor body.
2. Check that plunger and pinion return inward.
  If plunger and pinion do not return, replace magnetic switch.
  
  Fig 3: Disconnecting Negative (-) Lead From Starting Motor Body
  Courtesy of SUZUKI OF AMERICA CORP.
Perform no-load performance test as follows.
CAUTION:
- Use thick cable such as jumper cable, as large current may flow.
- Fix starting motor with vice or the like.
1. Connect battery and ammeter to starting motor as shown in figure.
2. Check that starting motor rotates smoothly and steadily with pinion moving out.
3. Check that ammeter indicates specified current.
  If check result is not satisfactory, repair or replace starting motor.
Specified current (No-load performance test)

90 A MAX. at 11 V

Fig 4: Connecting Battery And Ammeter To Starting Motor
Courtesy of SUZUKI OF AMERICA CORP.