Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1994 Suzuki SamuraiFACTORY OEM SERVICE PROCEDURE
Repair and Diagnosis: Electrical: Starter: Overhaul: Inspection: Commutator
- Inspect commutator for dirt or signs of burning. If dirt or burning is present, sand lightly with No. 300-400 sand paper or turn on lathe as necessary to clean surface.
- Using a dial indicator, check commutator for runout. Standard runout is .0019" (.05 mm) or less. Maximum runout is .016" (.4 mm). If runout exceeds maximum limit, replace commutator.
- Using a micrometer, measure diameter of brush end of commutator. Standard measurement is 1.26" (32 mm). Minimum measurement is 1.22" (31 mm). If measurement is less than minimum, replace commutator.
- Measure depth of insulator grooves between commutator segments. See Fig 1 . Standard depth is .016-.024" (.4-.6 mm). Minimum depth is .0078" (.2 mm). If measurement is less than minimum depth, replace commutator.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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