Starting Motor Operation Check

CAUTION: Sparks resulting from short circuit between the positive (+) and negative (-) terminals during connections to the battery could cause a burn. Be careful not to short-circuit the positive (+) and negative (-) cables and connect them only to the correct terminals.

NOTE: If battery power is applied too long in any of the following tests, the coil of the magnetic switch may burn. Each test must be completed within 3 - 5 seconds to avoid burning of the 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: Checking Pull-In Test
  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: Checking Hold-In Test
  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: Checking Plunger And Pinion Return Test
  Courtesy of SUZUKI OF AMERICA CORP.
Perform no-load performance test as follows.
CAUTION: If the cable used for the test is not adequately thick, the cable may become extremely hot due to large current flowing through it and you could get burned. Be sure to use a cable with thickness equal to or larger than the cable used between the vehicle's battery and the starter.
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: Identifying Battery And Ammeter Connection With Starting Motor
Courtesy of SUZUKI OF AMERICA CORP.