Page 1982 of 2453
SC(H6DO)-24
Generator
STARTING/CHARGING SYSTEMS
4. BRUSH
1) Measure the length of each brush. If wear ex-
ceeds the service limit, replace the brush. Each
brush has the service limit mark (A) on it.
Brush length:
Service limit (1)
5.0 mm (0.197 in)
Standard (2)
18.5 mm (0.728 in)
2) Checking brush spring for proper pressure
Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of brush
spring. If the pressure is less than 2.2 N (224 g, 7
91 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.8 to 6.0
N (489 to 612 g, 17.26 to 21.58 oz).
5. BEARING (FRONT SIDE)
Check the front ball bearing. If the resistance is felt
while rotating, or abnormal noise is heard, replace
the ball bearing
SC-00162
(A)
(1)
(2)
SC-00093
Page 1983 of 2453

SC(H6DO)-25
Battery
STARTING/CHARGING SYSTEMS
4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after discon-
necting the negative (–) terminal of battery.
2) Remove the flange nut from battery rod and re-
move battery holder.
3) Remove the battery.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
NOTE:
•Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
•Connect the positive (+) terminal, and then con-
nect the negative (–) terminal of the battery.
•Initial diagnosis of electronic control throttle is
performed after battery installation. Because of
this, start the engine 10 seconds or more after the
ignition switch is turned ON.
C: INSPECTION
WARNING:
•Electrolyte has toxicity; be careful of han-
dling the fluid.
•Avoid contact with skin, eyes or clothing. Es-
pecially at contact with eyes, flush with water
for 15 minutes and get prompt medical atten-
tion.
•Batteries produce explosive gases. Keep
sparks, flame, cigarettes away.
•Ventilate when charging or using in enclosed
space.
•For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a bat-
tery.
•Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
•To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle. This
may cause short circuit.
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and
terminal posts for dirt or cracks. If necessary, clean
with water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL
Check the electrolyte level in each cell. If the level
is below MIN level, bring the level to MAX level by
pouring distilled water into the battery cell. Do not
fill beyond MAX level.
SC-02100
Page 1984 of 2453

SC(H6DO)-26
Battery
STARTING/CHARGING SYSTEMS
3. SPECIFIC GRAVITY OF ELECTROLYTE
1) Measure specific gravity of electrolyte using a
hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20°C (68°F) us-
ing the following equation:
S20 = St + 0.0007 × (t – 20)
S20: Specific gravity corrected at electrolyte
temperature of 20°C (68°F)
St: Measured specific gravity
t: Measured temperature (°C)
Determine whether or not battery must be
charged, according to corrected specific
gravity.
Standard specific gravity: 1.220 — 1.290
[20°C (68°F)]
2) Measuring the specific gravity of the electrolyte
in the battery will disclose the state of charge of the
battery. The relation between specific gravity and
state of charge is as shown in the figure.
D: MEASUREMENT
WARNING:
Do not bring an open flame close to the battery
at this time.
CAUTION:
•Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
•Be careful since battery electrolyte overflows
while charging the battery.
•Observe instructions when handling the bat-
tery charger.
•Before charging the battery on the vehicle,
disconnect the battery ground terminal to pre-
vent damage of generator diodes or other elec-
trical units.
1. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte should be held
within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a spe-
cific value in a range from 2.5 to 2.8 V for more than
one hour.
2. CHECK CONDITION OF CHARGE WITH
HYDROMETER
3. NORMAL CHARGING
Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of battery's
ampere-hour rating.
4. QUICK CHARGING
Quick charging is a method that the battery is
charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temper-
ature, the battery is subject to damage if the large
current is used for prolonged time. For this reason,
the quick charging must be carried out within a cur-
rent range that will not increase the electrolyte tem-
perature above 40°C (104°F).
Also the quick charging is a temporary mean to
bring battery voltage up to some level, and battery
should be charged slowly with low current as a rule.
CAUTION:
•Observe the items in 3. NORMAL CHARGING.
•Never use more than 10 A when charging the
battery because it will shorten the battery life.
SC-00054
010 20 30 40 50 60 70 80 90 100
1.12
1.20
1.16
1.24
1.28
1.22
1.08
1.04
Amount of discharge (%)
Specific gravity ( C)
Battery with standard specific gravity 1,280 (20 C)
Good
Need to charge
Hydrometer
indicator
State of
chargeCorrective action
Green 65% or more Load test
Dark 65% or less Charge battery
ClearLow electro-
lyte
Replace the battery.*
(If cranking is difficult)
* Check electrical system before replacement.
Page 2365 of 2453
WI-81
Charging System
WIRING SYSTEM
18.Charging System
A: WIRING DIAGRAM
WI-08087
CHG-01CHG-01
F37A:
GENERATOR
BR
3
WB
1
WR
2W
REF. TO POWER SUPPLYCIRCUIT [P-SUP-02]
F26
i10A:
i11B:
COMBINATIONMETER
B9
BW
WB
B11
A7
B228
REF. TO ENGINGEELECTRICAL SYSTEM[E/G-01]
OP CONNECTOR
MAIN FUSE BOX(M/B)
13
F37
B143
A:
B:
F26
123
B228
131415
123456789101112
CHARGEWARNINGLIGHT
1234 5678910 11 12 13 14 15 16 17 18 19 20
B143B:
12345678910 11 12 13 14 15 16 17 18 19 20
L
L
i1
B40321
L
BW
TO POWER SUPPLY CIRCUIT
FB-36 F/B FUSE NO. 5 (IG)
123456789101112
i127(BLACK)
i126(BLACK)
i10
19 20 2115 16 17 18222324252627282930123456 8910 11 12 13 147
A:
BrW
A3A4
BrW
BrW
JOINT CONNECTOR
i126i127
1*
2*2*
i11
123 45678910 11 12 13 14
B:
567821943
10
2422 23 25
11121314151617181920 21
B403
: TERMINAL NO. OPTIONAL ARRANGEMENT AMONG 10, 11 AND 12
: TERMINAL NO. OPTIONAL ARRANGEMENT AMONG 7, 8 AND 9
1*
2*