ELECTRICAL SYSTEM

1. Starter
1.1 Inspection before Disassembly
(inspection of assembly)

Lightly press
the tip

If an abnormality is found, disassemble and repair.

(1) Pinion gap
(a) Connect the positive (+) cable of the battery to
terminal S of the starter and the negative (-) cable
to the starter body to extend the pinion.

Battery
12 V

Starter

0.5 to 2.0 mm
(0.0197 to 0.0787 in.)

Inspection of pinion gap

CAUTION
Switch

Do not supply electricity for more than 10

continuous seconds.

(b) Lightly press the tip of the extended pinion shaft

with a finger, and measure the distance of the shaft
movement.

Ammeter
A
Stater

Revolution
indicator

(c) If the measured value is not within a range of 0.5

to 2.0 mm (0.0196 to 0.0787 in.), increase or
decrease the number of packings at the magnetic
switch section for adjustment. An increase of
packings results in a decrease of the pinion gap.

No-load test

Standard
Value

Item

(2) No-load test

(a) As shown in the diagram, connect an ammeter,
voltmeter, revolution indicator and battery.
(b) Turning on the switch should extend the pinion and
operate the starter at the specified speed or faster.
If the current or rotating speed does not conform to
the standard value, disassemble the starter for
inspection and repair.

CAUTION
(1) Use thick wires, and tighten the connections
at the terminals.
(2) It should be noted that the rotation sound is
louder than the sound produced by a starter
without a reduction gear mechanism.
(3) When measuring the rotation speed at the
tip of the pinion, be careful of the pinion
extension at the start of operation.

12-1

Battery
12 V

Starter model

M8T75171

Nominal output

V-kW

12-2.2

No-load
Terminal voltage V
11
characteristics
Current
A 130 or lower
Rotation speed
min1

3800
or higher

ELECTRICAL SYSTEM

(3) Inspection of magnetic switch

Conduct the following inspection. If the magnetic switch is
faulty, replace.

S
M

(a) Disconnect the wire from terminal M.

(b) Suction test

Connect the battery to terminals S and M of the

magnetic switch. The pinion should extend when the
switch is turned on.

Battery
12 V

Disconnect connector

Suction test

CAUTION
Do not supply electricity for more than 10
continuous seconds.
(c) Holding test
With the battery connected to terminals S and the body
of the magnetic switch, pull out the pinion fully with
fingers. The pinion should not return to the original
position when it is released.

Disconnect
connector

S
M

Battery
12 V

CAUTION
Do not supply electricity for more than 10
continuous seconds.

Holding test

(d) Return test

With the battery connected to terminals M and the body
of the magnetic switch, pull out the pinion fully with
fingers. The pinion should return immediately to the
original position when it is released.

Disconnect connector
M

Battery
12 V

CAUTION
Do not supply electricity for more than 10
continuous seconds.

12-2

Return test

ELECTRICAL SYSTEM

1.2 Disassembly
2

17
18
Surface clearness of commutator,
seizure, wear, worn or damaged gear,
and disconnection.

16

Replace snap ring.

Check for wear
or damage.

Check for rotation.

Check for rotation.

9

8
1

11
Accumulation of brush dust,
uneven wear or sticking in holder.

Check for slippage

or seizure.

13

12
14

Replace washer.
Check gear for worn
or damaged teeth.

15

3
4

Pole and field coil

installation conditions.

Disassembly sequence
1
2
3
4
5
6

Pinion set
Magnetic switch
Rear bracket
Brush holder assembly
Yoke assembly
Armature

7
8
9
10
11
12

Bearing
Ball
Packing set
Gear
Lever assembly
Washer set

12-3

13
14
15
16
17
18

Gear shaft
Internal gear
Overrunning clutch
Front bracket
Bearing
Oil seal

ELECTRICAL SYSTEM

CAUTION
Before disassembling or replacing the following
parts, remove the pinion.
Remove the pinion before disassembling:
(1) Front bracket, or bracket bearing and oil
seal
(2) Reduction gears
(3) Overrunning clutch
(1) Removing pinion
Supply electric current to the switch to set the pinion in the
protruded condition. Remove the M-terminal connector,
and connect the battery and starter, as shown in the diagram.
Close switches S1 and S2 to set the pinion in the protruded
condition. Then, open switch S2 to stop the pinion rotation.
Set a pipe-shape tool on the pinion stopper, and lightly tap
the tool with a hammer to remove the pinion.
In some cases, the stopper does not dislodge from the
position and the pinion retracts into the original position.
When this happens, repeat the procedure.

S1
B
S

S2

Battery
Stater

Removing pinion

(2) Ball
The ball serving as the bearing in the armature thrust
direction may be stuck to grease on the tip of the shaft when
the armature is removed. Do not loose this bearing ball.

12-4

ELECTRICAL SYSTEM

1.3 Inspection
(1) Armature
(a) Testing for short circuits
Place the armature on a growler, and slowly revolve it
with a hacksaw blade held above the armature core.
The hacksaw blade vibrates against the core when it is
above a slot containing a shorted winding. Replace the
armature if shorted.

Testing short circuits

(b) Testing for grounded circuits

If there is any continuity between the commutator and
shaft (or core), the armature is grounded and should be
replaced.

Testing grounded circuits

(c) Inspecting commutator

1) Support the armature in V-blocks and measure the
runout of the commutator with a dial indicator. If
the runout is near the service limit, recondition the
commutator, making sure the commutator diameter
does not exceed the service limit.
Unit: mm (in.)
Item

Assembly
Standard

Service
Limit

Runout of commutator

0.05 (0.002)

0.10 (0.004)

Measuring the runout

2) Measure the diameter of commutator. If it is

smaller than the service limit, replace the armature.
Unit: mm (in.)
Item
Diameter of
commutator

Assembly
Standard

Service
Limit

32 (1.26)

31.4 (1.236)

Measuring the diameter

12-5

ELECTRICAL SYSTEM

3) Measure the depth of each mold between segments

with a depth gauge. If the depth is less than the
repair limit, recondition the mold.

Mold depth
Segment

Unit: mm (in)
Item
Depth of
commutator mold

Assembly
Standard

Repair
Limit

0.4 to 0.6
(0.016 to 0.024)

0.2 (0.008)
or less
Measuring the mold depth

4) Inspecting armature gear

Check the armature gear for abnormal wear and
missing teeth, and replace it if necessary.
(2) Field coil
(a) Testing for open circuits
If there is no continuity between the lead wire and
positive (+) brush, the field coil is open and the yoke
assembly should be replaced.

Testing yoke coil for open circuit failure

(b) Testing for grounded circuits

If there is no continuity between the yoke and positive
(+) brush, the insulation and repair or replace the yoke
assembly.

Testing yoke coil for grounding failure

12-6

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(3) Magnetic switch

S terminal

(a) Testing coil for open circuits

If there is no continuity between S and M terminals
and between S terminal and body (ground) , replace the
switch.

B terminal

M terminal

(b) Checking contactors for fusion

If there is continuity between B and M terminals,
replace the switch.
(c) Checking contactors for poor contact action

Testing magnetic switch

Check for voltage drop. If voltage drop is excessive,

the contactors are defective.
(4) Brushes and holders
Brush

(a) Wear of brushes

Measure the brush length and, if it is less than the
service limit, replace the brushes. If the brushes are
unevenly worn or rough, recondition them with a
sandpaper of #300 to #500.
Unit: mm (in)
Item
Length of brush

Assembly
Standard

Service
Limit

18 (0.71)

11 (0.43)

Measuring brush length

(b) Brush spring force

Test the spring force using a new brush. In the test,
read the road at the instant the spring moves off the
brush. If the force is less than the service limit, replace
the spring.
Unit: N (kgf) [lbf]
Item

Assembly
Standard

Service
Limit

Force of brush spring

26 to 36
(2.7 to 3.7)
[5.8 to 8.1]

15
(1.5)
[3.4]

Measuring rush spring force

12-7

ELECTRICAL SYSTEM

(c) Testing brush holders insulation

If there is any continuity between the positive (+) brush
holder and negative (-) holder plate, replace the brush
holder assembly.

Testing brush holders insulation

(5) Inspecting bearings

Check the bearings and replace any that fails to turn
smoothly or emits noise.
(6) Inspecting overrunning clutch
(a) Make sure that the pinion shaft turns freely when
turned in the direction of driving (clockwise) and it
is locked when turned in the opposite direction.
(b) Check the overrunning clutch for worn-out or
damaged pinion, and replace it if necessary.

CAUTION
Do not wash overrunning clutch in wash oil.
Inspecting overrunning clutch

(7) Front bracket

If the ball bearing fails to turn smoothly or emits noise,
replace it together with the front bracket.

NOTE
Replace the oil seal at every disassembly.

(8) Reduction gear

Replace the reduction gear if it is worn out or damaged.

12-8

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1.4 Reassembly
To reassemble, follow the disassembly sequence in reverse.
(1) Applying grease
When overhauling the starter, apply grease to the following sliding parts, gears, and bearings.

2
8
6
3

Reassembly sequence
1
2
3
4

Armature shaft gear

Armature rear bearing (Slightly. Be careful not
to let the grease enter the commutator.)
Reduction gear
Pinion shaft gear

5
6
7
8

Lever sliding section of magnetic switch

Pinion shaft bearing
Pinion
Oil seal

(2) Installing stopper ring

Fit the stopper ring into the ring groove on the pinion shaft.
Then, using a puller, pull the pinion stopper over the
stopper ring to fit the stopper ring into the ring groove
inside the pinion stooper.

Pinion stopper
Stopper ring

Pinion
stopper

Installing stopper ring

12-9

ELECTRICAL SYSTEM

(3) Adjusting pinion shaft end play

Using an appropriate number of adjusting washers in
between the center bracket and reduction gear, adjust the
end plate (thrust gap) to 0.5 mm (0.020 in.) or less.
(a) Assemble the pinion shaft, reduction gear, washer
and snap ring to the center bracket.
(b) Moving the pinion shaft in the axial direction,
measure its end play. If the end play exceeds 0.5
mm (0.020 in.), increase the number of adjusting
washer as required to reduce it to 0.5 mm (0.020
in.) or less.

Reduction gear
Adjusting
washer
Washer
Snap ring

End play
0.5 mm (0.020 in.)
max.

Adjusting pinion shaft end play

(4) Installing lever

Front bracket

Install the lever facing in the correct direction.

Lever
Lever spring

Packing

Installing lever

1.5 Inspection and Adjustment after

Assembly
Following inspections and tests shall be performed after
starter assembling.
(1) Checking pinion gap
With the pinion fully protruded, lightly press the pinion
shaft end back with a finger. Measure the extent of shaft
return to determine if the pinion gap is larger or smaller than
0.5 to 2.0 mm (0.0196 to 0.0787 in.). Make adjustment, if
necessary, with the packing provided where the magnetic
switch is fitted; increase the number of pieces of packing if
the gap is larger and decrease otherwise.

Lightly press
the tip

+
Battery
12 V

Starter

0.5 to 2.0 mm
(0.0196 to 0.0984 in.)

Adjusting pinion gap

(2) No-load test

Ammeter

After adjusting the pinion clearance, hook up the starter as

shown, and test it for no-load characteristics.

Switch

CAUTION

Use thick wires as much as possible and tighten

each terminal securely.
Item
No-load
characteristic

Voltage

Current

Speed

11 V

130 A
or less

3800 min1
or less
12-10

Battery

Voltmeter

No-load test

B
M

Switch

ELECTRICAL SYSTEM

2.

Alternator

If a problem occurs in the charge system, check the

following abnormal conditions to locate the cause of the
problem. Only when inspection cannot be conducted on
the alternator installed on the engine, dismount the
alternator for inspection and repair.
Overcharging

Voltage regulator adjustment value is high.

Overdischarging

Voltage relay adjustment value is low.

Faulty battery.
Faulty alternator output.

Alternator

Power consumption is extremely high.

Special load is used.
Faulty wiring.

2.1 On-vehicle Inspection

(1) Cautions in handling
Handle the alternator carefully. Incorrect handling can
result in alternator damage and malfunctions.
(a) Do not connect the battery cables in reverse. Note
that the negative cable is a grounding wire.
(b) Do not use a high-voltage tester such as a megger.
(c) When charging the battery, disconnect the cables
from the battery terminals.
(d) Do not disconnect the lead wire from terminal B of
the alternator while the engine is operating.
(e) Do not ground terminal B of the alternator since it
is constantly applied with battery voltage.
(f) Do not short or ground terminal L (unit with
integrated IC regulator).
(g) When using a steam cleaner, do not allow steam to
directly contact the alternator.

12-11

ELECTRICAL SYSTEM

(2) Inspection of adjustment voltage (unit with

integrated IC regulator)
(a) Disconnect the cable from the positive (+) terminal
of the battery, and connect an ammeter between the
terminal and cable.
(b) Connect a voltmeter between terminal L and
ground.
(c) Make sure that the voltmeter indicates 0 when
the starter switch is turned off.
Make sure that the voltmeter indicates a voltage
level sufficiently lower than the battery voltage
when the starter switch is turned on (without
starting the engine).
(d) Short-circuit the terminal of the ammeter, and start
the engine.
(e) Read the indication (adjustment voltage) on the
voltmeter with the ammeter indicating 5 A or
lower, the engine operating at 1800 to 2500 min-1,
and the lamp switches turned off.

Ammeter
+

Switch

Battery

R
+
V Voltmeter

12 V

Inspection of adjustment voltage

Unit: V
Item

Standard Value

V-A

Adjustment voltage
at 20C (68F)

14.70.3

12-50

(3) Inspection of output (unit with integrated IC regulator)

Ammeter
A

(a) Disconnect the grounding cable from the battery.

(b) Disconnect the wire from terminal B of the
alternator, and connect an ammeter. Connect a
voltmeter between terminal B and ground.
(c) Connect the grounding cable to the battery.

Voltmeter
V

Charge
lamp

L
Switch

(d) Start the engine.

(e) Immediately after the engine starts, turn on all load
devices such as lamps.
(f) Increase the engine speed. When the voltmeter
indicates 13.5 V, read the maximum current at the
specified alternator rotation speed.
If the measured value conforms to the standard
value, the alternator is normal.

Wiring diagram for output test

(unit with integrated IC regulator)

Output characteristics
Standard Value
Item

Model

Terminal
voltage/
current

Rotation
speed

Option
13.5V/33A 2500 min-1
characteristic A7TA0477A
13.5V/47A 5000 min-1
(when warm)

12-12

ELECTRICAL SYSTEM

2.2 Disassembly
5
Check slip rings for clearness, damage
and seizure. Check for coil resistance.
10

Check for rotation.

4

3
Check for sliding condition
and wear of brush.

Check for rotation.

1
7

Check for short or

open circuit.

Check coil for disconnection or grounding.

Disassembly sequence
1
2
3
4

Nut
Pulley, Spacer
Screw
Front bracket assembly

5
6
7
8

Rotor assembly
Stator
Rear bracket
Regulator assembly

12-13

9
10

Rectifier assembly
Nut set

ELECTRICAL SYSTEM
Key points in disassembly

(1) Separation of front bracket from stator core

(a) Insert the tip of a slotted screwdriver into the gap
between the stator core and front bracket, and pry
open.

CAUTION
Do not insert the screwdriver too deep into the
assembly to prevent damage to the stator core.
Disassembly of alternator

(2) Removal of pulley

(a) Wrap the rotor with a cloth for protection, and hold
it with a vice. Unscrew the pulley nut, then
remove the pulley and spacer.
(b) Remove the rotor from the front bracket.

Removal of pulley

(3) Removal of stator core and rectifier

(a) Disconnect the lead wires from the stator core to
the rectifier at the soldered sections. Then, remove
the stator core.

Solenoid sections
Rectifier

CAUTION
Melt the soldered sections as quickly as
possible. If heat is applied for an extended
period of time, the diodes can be damaged.
(b) Unscrew the rectifier mounting screws, and
dismount the rectifier.

12-14

Solenoid
section

Removal of stator core

ELECTRICAL SYSTEM

2.3 Inspection
Key points in inspection

(1) Inspecting diodes

Trio diodes

For inspection of individual diodes, check the resistance

between each diode lead and heat sink. Take resistance
measurements by connecting the positive (+) wire of a
tester to the diode and also by connecting the negative (-)
wire to the diode. If the resistance shows infinite in both
measurements, there is an open circuit. If the resistance is
close to 0 in both measurements, there is a short circuit.
If there is an open or short circuit, the diode is faulty and
the rectifier must be replaced.

() heat sink

(+) heat sink

Diode lead

Inspecting diodes

(2) Inspecting field coil

(a) Check the resistance between slip rings and if the
measurement does satisfy the standard value,
replace with a new rotor.
Item

Standard Value

Resistance between slip rings

2.7 to 3.2 ohm

Field coil continuity

(b) Check the continuity between the slip ring and

shaft (or core).
If there is electric conduction, the field coil is
grounded: replace the rotor with new one.

Field coil grounding test

12-15

ELECTRICAL SYSTEM

(3) Inspecting stator core

(a) Check the continuity between the stator core and
each lead wire.
If there is no electric conduction, there is an open
circuit: replace the stator core with new one.

Stator core continuity test

(b) Check to make sure that there is no continuity

between the lead wires and core.
If there is continuity, the circuit is grounded:
replace the stator with new one.

Stator core grounding test

(4) Inspecting brushes

(a) If the brushes are worn close to the wear limit line
(service limit), replace the brushes.
5 mm (0.197 in.)

Unit: mm (in.)
Item
Brush length

Assembly Standard

Service Limit

18.5 (0.728)

5 (0.197)

18.5 mm
(0.728 in.)

Wear limit line

Inspecting brush

(b) Disconnect the brush lead wires at the soldered

sections to remove the brushes and springs.

Soldered sections

Replacement of brushes

12-16

ELECTRICAL SYSTEM

(c) To install new brushes, press them into the brush

holders as shown in the illustration, then solder the lead
wires.

Replacement of brushes

2.4 Reassembly
To reassemble, follow the disassembly sequence in reverse.
Be sure to observe the following during assembly.
Key points in reassembly

Wire

(1) When press-fitting the rear bearing into the rear

bracket, heat the rear bracket to 50 to 60C (122 to
140F).
(2) The brushes must be raised before the rotor is installed
to the rear bracket. To do so, put a wire through the
small hole located on the rear bracket, then remove the
wire after completing the reassembly.

Rear bracket
Brush
Wire

Reassembly of alternator

2.5 Installation
(1) Install the fan belt on the alternator, and mount the
alternator on the engine.
Temporarily tighten all the bolts.
(2) Insert a bar between the alternator and crankcase.
Using the bar as leverage, move the alternator and
adjust the belt tension.
While keeping the alternator at that position, tighten
the bolt that secures the alternator to the adjusting
plate.
Installation of alternator

12-17

ELECTRICAL SYSTEM

(3) Check the belt tension. If the belt tension does not
conform to the standard value, loosen the belt and
repeat the above step (2).

Bolt

98 N
(10 kgf)
[22 lbf]

Water pump
pulley

Unit: mm (in.)
Item
Belt tension
(crankshaft pulley
alternator pulley)

Adjusting
plate

Standard Value
10 to 12 (0.39 to 0.47)
(when pressed with force of
98 N (10 kgf) [22 lbf])

(4) When the belt tension is properly adjusted, tighten all

the bolts that secure the alternator in place.

10 to
12 mm
(0.39 to 0.47 in.)

Alternator
pulley
Bolt

Inspection of belt tension

3. Glow Plugs
3.1 Inspection
As shown in the illustration, check the conductivity
between the terminal and body. If there is no conductivity
or if the resistance is high, replace the glow plug.
Item
Resistance

Assembly Standard
0.2 ohm

Inspecting glow plug

3.2 Installation
(1) Install the glow plug in the cylinder head by tightening
to the specified torque.

Tightening torque

182 Nm
(1.80.2 kgfm)
[131 lbfft]

(2) Install the connection plate to the glow plug, and

tighten the retaining nut to the specified torque.

Tightening torque

1.30.2 Nm
(0.130.02 kgfm)
[0.960.14 lbfft]

12-18

Crankshaft
pulley

ELECTRICAL SYSTEM

4. Magnet Valve (Stop Solenoid)

4.1 Inspection
(1) Check the conductivity between the terminal and body
as shown in the illustration. If there is no conductivity
or if the resistance is lower than the standard value,
replace the magnet valve assembly.
Item

Standard Value

Resistance
[Ambient Temp: 235C (73.49F)]

8 to 9.2 ohm

Checking magnet valve (1)

(2) Check visually for rubber strips of the tip of the

armature and damages. Also check the armature moves
smoothly by rotating with a hand.

Armature

Checking magnet valve (2)

4.2 Installation
Install the magnet assembly to the distributor with the
specified torque.

Tightening torque

Magnet valve
assembly

205 Nm
(20.5 kgfm)
[153.6 lbfft]
Injection pump
distributor head

Installing magnet valve

12-19