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
Starter Specifications
STARTER SPECIFICATIONS
| Application | Specification | |
|---|---|---|
| Brush Length (Except 2003-04 Grand Vitara & XL-7) | ||
| Standard | .48" (12.3 mm) | |
| Wear Limit | .28" (7 mm) | |
| Brush Length (2003-04 Grand Vitara & XL-7 ) | ||
| Standard | .48" (12.3 mm) | |
| Wear Limit | .21" (5.3 mm) | |
| Commutator Outside Diameter | ||
| Standard | 1.16" (29.4 mm) | |
| Wear Limit | 1.13" (28.8 mm) | |
| Commutator Out Of Round | ||
| Standard | .002" (.05 mm) | |
| Wear Limit | .016" (.4 mm) | |
| Direction Of Rotation | Clokwise as viewed from pinion side | |
| Insulator Depth | ||
| Standard | .016-.024" (.4-.6 mm) | |
| Wear Limit | .008" (.2 mm) | |
| Rating | 30 seconds | |
| Output | ||
| 2002-04 Vitara, ( Except 2003-04 Grand Vitara & XL-7) | 1.2 kW or 1.4 kW | |
| 2003-04 Grand Vitara & XL-7 | 1.4 kW | |
| Voltage | 12 Volts | |
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.