Page 1705 of 3573
STARTING SYSTEM 6D2 Ð 11
MAGNETIC SWITCH
Pull-out test
Connect the magnetic switch to the battery as shown.
The negative side to the ÒMÓ terminal and the magnetic
switch body (housing); the positive side to the ÒSÓ
terminal. If the pinion has been ejected, the pull-in coil is
satisfactory
Hold-in test
1. Next disconnect the ÒMÓ terminal.
2. The pinion should remain the ejected position
Return test
When the switch body is disconnected, the pinion should
return quickly
Page 1706 of 3573
6D2 Ð 12 STARTING SYSTEM
MEMO
Page 1707 of 3573

CHARGING SYSTEM 6D3 Ð 1
SECTION 6D3
CHARGING SYSTEM
CONTENTS
PAGE
General Description ........................................................................................................ 6D3-1
Diagnosis ......................................................................................................................... 6D3-4
Unit Repair ....................................................................................................................... 6D3-5
GENERAL DESCRIPTION
The generator does not require particular
maintenance such as voltage adjustment. The
rectifier connected to the stator coil has nine diodes
to transform A.C. voltage into D.C. voltage. This
D.C. voltage is connected to the output terminal of
generator. The charging system is the IC integral regulator
charging system and its main components are
connected as shown in Figure.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
Page 1708 of 3573
Page 1709 of 3573
Page 1710 of 3573
6D3 Ð 4 CHARGING SYSTEM
DIAGNOSIS
GENERAL ON-VEHICLE INSPECTION
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes on
when the starter switch is turned to ÒONÓ position. The
charging system operates normally if the lamp goes off
when the engine starts. If the warning lamp shows
abnormality or if undercharged or overcharged battery
condition is suspected, perform diagnosis by checking the
charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine in stop status, turn the starter switch
to ÒONÓ position and observe the warning lamp.
·If lamp does not come on:
Disconnect wiring connector from generator, an
ground the terminal ÒLÓ on connector side.
·If lamp comes on:
Repair or replace the generator.
Page 1711 of 3573
CHARGING SYSTEM 6D3 Ð 5
UNIT REPAIR
Disassembly Steps
1. Vacuum pump
2. Through bolt
3. Pulley nut
4. Pulley
5. Fan
6. Rotor
7. Spacer
8. Front cover assembly
9. Bearing retainer
10. Front bearing11. Rear bearing
12. Terminal bolt and nut
13. Rear cover
14. Stator
15. Diode
16. IC regulator assembly
17. Brush holder
Reassembly Steps
To reassemble, follow the disassembly steps in the
reverse order.
Page 1712 of 3573

6D3 Ð 6 CHARGING SYSTEM
DISASSEMBLY
1. Vaccum Pump
¥Dram fluid from discharged port.
¥Remove the vacuum pump fixing bolts. Hold the
center plate and remove the vacuum pump
horizontally in direction in line with the rotor
shaft.
2. Through Bolt
3. Pulley Nut
¥ Cover the vice with copper plates, clamp the rotor
with vice, and remove the nut.
4. Pulley
5. Fan
6. Rotor
7. Spacer
8. Front Cover Assembly
9. Bearing Retainer
10. Front Bearing
11. Rear Bearing
12. Terminal Bolt and Nut
13. Rear Cover
¥ Remove the nuts fixing the B terminal and diode
holder.
Separate the stator and rear cover.
Note the position of insulation washers to ensure
reassembly into original position.
14. Stator
15. Diode
¥ Separate the diodes from the stator by melting
away solder on stator coil and diode.
When melting solder, hold the lead wire with
longnose pliers to prevent heat from being
transferred to the diodes.
16. IC Regulator
¥¥ Separate the IC regulator from the diode by
melting away solder on IC regulator holder plate
and removing the nut.