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.
2002 Suzuki XL-7 PlusFACTORY OEM SERVICE PROCEDURE
Bench Testing: Armature
- Inspect commutator for dirt or burn. See Fig 1 . Correct with sandpaper or lathe as necessary.
- Check commutator for uneven wear with the armature (1) supported on V-blocks (2). See Fig 2 . If deflection of dial gauge (4) pointer exceeds limit, repair or replace. See STARTER SPECIFICATIONS
- Inspect the commutator for wear. See Fig 3 . If diameter is below limit, replace the armature.
- Inspect the commutator (1) for insulator (2) depth. See Fig 4 . Correct or replace if it is below the service limit.
NOTE:
The following specification presupposes that the armature is free from bend. Bent armature must be replaced.
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.