MODEL

J13, J15 & J16 SERIES

Et{Gt1{ES
 EngineElectricalSystem

STARTINGCIRCUIT

The electricalsystemk a 12 volt Startingmotor Infomation on body electrical

sFtem. This sectionis subdividedinto systemssuch as lighting, instrum€nt,
the following subsectionsfor el€ctrical R€gulator and windshield wipers is deecribedin
parts which are required for engine Dstributor s€ction BODY ELECTRICAL in
opention. Ignitioncoil CIIASSISANP BODY.
. Battery Sparkplug

BATTERY
CONTENTS
RE\,4OVAL AND II\STALLATIO\ ,, ,, Ea-2 B A T T E R YF R E E Z I N G.. EE.3
RETVOV . .A
. .L. . . . . . . EE.2 ADJUSTING S P E C I F I CF A V I T Y, . . , , . . , , , E E - 4
G
\STALLATION EE.2 C H A R G TCNTGR C U. .T. T. . . . . . . . . . . . . . . . . . . E
. E.4
ELECTROLY LE TE V EC L H E C,<, , , , , , , , TROUELEDIAGNOSES AND
S P E C TG
FRTC ATVYC H E C < . . . . . . . . . . EE-3 conREcTtoNs ....... EE-s

REMOVALAl{D
Itt|STALLATIOt{ ffi J=l=
@
l_r
REMOVAL
l Disconnect
tarminals.
andposltlve
negative

2. Renovenutsfiombatteryclamp;
#@
+
tal(eout clamps,

1r
3. R€move battery.

tI{sTAttAiflo
l. Install and tighten clamps 3€.
curely.
2. After clampshavebeen tightened,
cleanbattery cableterminalsand ap"
ply gr€as€ to retard formation of fig. EE-1 l$pecting electrolrte le@l
corrorion.

ELECTROLYTE
LEVEL CHECK
Ch€ck the electrolyte level in each l. Unscr€weachfiller aap and in,
battery cell onc€a month. spectfluid level,which canbe deter
mined by glancing into the cap
In caseof batterywitl fluid level
openings.SeeFigure EEI
lines, check to se€that the level is
Determine asshownbelow:
betweenthe upper and the lower lev€l
lines. Fig. EE-2 lupecAry electrclrte leuel
(uith te@l tines)

EE.2
 Engine Electrical System

lf the fluid levelis low, and distiled
water for each cell to raise the level
approximately l0 to 20 nm (0.394to
0.787 in) sbovethe plates.ln cale of
battery with l€vel lines, add distilled
$ater to the upper level. Do not
overfill.
SPECIFICGRAVITY
CHECK
Specificgra ty of batteryelectro_
lyte is testedby a hydrometer.
l. When measuring speclficgravlty,
place your eyes in line with scaleto
readhighestlevel(elecholytedsesat
edgedueto surfacetension)ofeleclro..
lyte. SeeFigureBB-3.
A corr€ction can ther be madeby The state of chargeof battery can
usingthe following formula: be determinedby the following tabl€s
Sro = St + 0.0007(t 20) if the specificgravity of electrolyte is
knorvn.Beforechecking,checkto be
S?o: Specific gravity ofelectrolyte sure tbat cells are filled to correct
correctedat 20oc (68oF) lev€1.
St: Specificgravity of electrolyte
at toc
t: Electrolytetemperature
.O
For example; A hydrometerreading 3
of 1.260 at 30oC (86oF) would be C
1267 whencorrected at 20oC(68oF), g
indicating fully clnrged battery. On L
the other hand,a hydrometerreading
ol 1.220at -IooC (14oF) would be
1.199whencorrected at 20oC(680F),
Ee002
FiE.EE-4 Relationbetueenspecific
indicatinga partiallychargedbattery. Ertoitr ond chotRinq condition
Conv.ttcdspscificgrdlty (S20)

sNffi
l-\ <t-h
E
[<

iL-F
iL-F
-'i

s
'6
-'j

:l ih-h

-u
--1=-l'--
L- tL
0
ffi
f"(T-l
1l 2a Ja "-ii --fr
Elecilolyk temprEtu,. roC)
FiE-EE-, ChanAesof Epecific ercuity in rcsponse to
electrolrte t?mp.tutur..hohg. (oC)

Fig-EE-3 CheckingspecificErcvity
2. If the stateofchargeof batieryis
607, full, or specific-gravityreadingis
below 1.20 las correctedat 20oC
(68oF)l, batieryrnustbe recharged or
batteryalectrolyte concentration must
be adjusted.
Add or subtractgravitypointsac'
cording to lrihether t}e electrolyte
temperatureis aboveor below20oC
(68"F) standard.
The gravity of electrolyt€ changes
0.0007 for every l"C (33.8oF)ten-
BATTERY FREEZING
Temperatures at whichbatteryelec-
trolyte l-reezesvary with acid con-
centrationor its specilicgravity.A
battery vrith an insufficient state of
chargewil freezeat low temperatures.
If specificgravity of a battery fails
below1.100,th€ indicationir tlat the
battery is completelydischargcdand
wili freezer€adilywhentemperatures
fall below freezingpoint. SeeFigure
EE{.
Note: Us€ extrerne caution to avoid
freezingbattery sinceit will usualy
ruin the battsy.
 EngineElectricalSystem

0 CHARGINGCIRCUIT
iEi!*-
- -i0 Baitery must be rechargedwhen
i -zo
tiiijh standard €lectroh/te.gravity reading
falls belorv 1.200wiih electrolj,'televel
E being satisfactory.If battery is quick-
& . ^
'6 chargedto bring it up to fuu charge,
-40 \
F ''{}} th€ operation should be cafiied out
with negativeterminal rcmoved.
I
!
-50
*ft\ Prior to charging,corroded termi
nals should be cleanedwith a brush
E -50 'ti\ and commonbaking-soda solution.In
E fi addition, the following items should
?i
-80 $f be oblervedduringrechaqingbatteryi

t . 0 0 L o 4 1 . 0 8 l . l 2 1 . 1 61 . 7 0 1 . 2 41 . 2 81 . 3 2 l. Be surethat elecirolytel6vel ls
Specific giady of electrolyo abovetop of eachplate.
2. K€ep removedplu$ in a safe
I'ig. EE.6 lrcezinc point ofelectrclyte location.
AD'U6II1{G SPECIIIC 3. Do noi allow electrolytetem-
perahrre togo over45oC(1l30F).
GRAVITY Whenlower,adddilutedsulphurlcacid 4. After recharging,check to be
Besureto checkelectrolyle speclfic lspecificgravityof which is 1.400at certainthat stsndardspecificgravity
gavity after firlly charglng battery. 20.c(68.F)l. doesnot excoed1.260 ht 20oC(680
Standardsp€cilicgravity b 1.260at Whenadjustin8speclJlcgravily,be F)l . Corr€ctioncsn be madeby add-
20oc (68oF). sure to conv€rtmeasured sp€cific ing disiilledwaierto collsasnecesrary.
Wh€nspecificg.avity i6 higherthan gravityto standard specific gravityat 5, Keep batt€ry away fiom open
the stlndrrd value,add distilled wster, 20oc(68oF). flamewhilolt l!being recharged.
6, After all vent plu$ have been
tlghtened, cleanupperfaceofbattery.
tp.cillc lrlvlty rl.40O

!g 2ao
t; 11
:E 18!

!E l::
€in
i6 go
El *
;F :3
r,?70r.?& r?90!.3o
t,2!J .Un r.?!0r.?60,
1,121
So.cllicrrlvlty llt 2ooc l68oFll

Fig. EE-7 Adjwtins specific gftuitr

EE-4
 EngineElectricalSystem
-TROUBLE DIAGNOSES AND CORRECTIOT{S

Battery is not chargedcorrectly.

l. Correctly adjustbelt tensionof alternatot.
2. Completeconnectionsin charglngsystem.
3. Securelyconnectbatterytelminals.

Lightingloadtest
1. MakeiurethatelectrolytelevellsconeCt.
(wlth ignltionsystemop€n).
2. Clankenginefor tlueeseconds
3. Turn on headlightoow beam)for oneminute,andthenmeasuespecilic
gravityof€achcellofbattery.

Specificgravityof eachcell is lels Specificgroviiy of somecella ia Specificgravityof eachcellIsabove

than1,200. above1.200but the otle$ show 1.20.
l. Wh€nspecific gravitycsnnotbe. lower
sp€cificgravity.
raisedabove1.200by charglng,
thebatteryIr defective.
Unbalance
is within 005 Unbalanceof spedfic gravity be-
l. DischarSedbattery. Charge it tweencellsexceed!005.
lnd repeatllghtingloadt$t. l. B.tteryisdefective.

ld wllhln 005.
Unbalance Unbalanceof speciflcgrevlty be.
l. Baiteryls satisfactory. tw€€nc€lls€rrceeds
0.05.
l. Battery
is defective;

f

D - S C oD r O \
OPERATION
c o N st c . .- o \
F.[/OVAI A\D \S-a tA tO\ ... ...
D < ^ . ) t t v B t\
c r f a \ ' \ - A \ D \ J P tC t O \ . . . . . . . . . .
_FF\4
\A1 .,.
F t l - L DC O t '
...
B R U S H L SA \ D B R J S -
B D L I C SHP R . \ ' T F N S O \ . . . . . . . . . .
^ D \ r A T U o a 5 _ t V BY t
( _u - c - a J 5 : \ 4 8 Y .
-fq
BRUShHO_DrB ' oc Gqou\D
DESCRIPTION
Thefunctionofthe startingsystem,
consislingof the battery, ignilion
sw'tch,sta(in8 molor and solcnoid,is
to crank the engine.Tbe electrical
OPERATION
Whenthe ignition swilchis turned
tully clockwiseto the START posi-
tion! batt€ry current flows through
"series" and "shunt"
coils of the
solenoid.magnetizingthe sol€noid.
The plungeris pull€dinto the solcnoid
so that il operaiesrhc shift ievcr to
move the drive pinion into the fly,
wheel fing gear.Then the solenojd
switch conracrscloseafr€r the drive
pinion is partially engaged with the
ringgear.
Closingof the solcnoidswitchcon-
tacts causesthe molor to crank the
engjneand also cut out rhe'\eries"
Engine ElectricalSystem
STARTINGMOTOR
CONTENTS
P ] N I O NC A S EB E A R ] N GM E T A L , . , , , . , . E E . 9
E E 6 MAGNET1C S W I T C HA S S E M B L Y, . , . , , , , E E 9
A S S E I \ 4 B 1 Y . .. .. .. . . . . . . . . . . . . . . . . . . . . E E -9
T E S T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _E. E .to
PERFOFN4AN TE CS E T. . . _ . . . . . . . . . . . . . . . E E - ] O
E E .8 DIAGNOSE O SF T E S T. . . . . . . . . . . . . . . . . . . E E - I O
EE 8 M A G N E T I CS W T C H A S S E N I B L T YE S T
., EE.IO
EE 8 S E F V I C ED A T A A N D S P E C I FC A T O N S , , . , E E 1 ]
AD W R EE.8 S E R V I CDEA T A. . . . . . . . . . . . . . . . . . . . . . . . E E _ 1 1
E E 8 SPECC I FA T I O N. S_ . . . . . . . . . . . . . . . . . . . . .E E t 2
.TBOUB
..... .. EE.8 LE DIAGNOSES AND
E E 9 C O R R E COTN S
. . . . . . E E1 3
EE.9
energyis suppliedfron thc ba$ery, coil bccomeszefo. The relurn spring
the solcnoidcompletesthe oircuit to then actuatesthe shift lever rvhich
operrte the startingrnotor, and then puilsthe plungcr,andallowsit to opcn
the motor carricsout the actualcrdnk. the solcnoidswitch conraols.Conse-
ingof the enginc. quenlly,thestartingnrotorstops,
a,
@
o
3 Shilt l.vcr
4 Ovclrurning ctutcll
@ @
I Stdtionrry contlct 8 Shill tevel
2 Sericscoil 9 Drivc pinion
FiE. EE-8 Sectionaluiew of startinemotor 3 lAnition switch 10 Rinr scrr
4 Solcnoid 1l linion slccvesprins
5 Shuntcoil 12 Annarurc
6 Plunecr l3 MovableoontdrLr
7 Relurn sprins t4 Brttcry
coil of the solenoid,the nagneric pull
of thc "shunt" coil beirB sufficient to Fig, EE-g SLartiag molar cncuit
hold thc pinion in mesh aftcr thc
shifling has beenperforned- More positjvemcshingand dcrncsh
A f t e r t h e e n g i n es t a r t sr u n D i i g , l h e ing of the pinion and the rins gear
d.iver feleasesthe ignition key and it tccth are sccured by mcans of the
automatically retuins to the ON posi- overiunning clutch. Thc over-running
clutch ernploys a shift lcvcr to slide
This breaks the solenoid circuit so the pinion akrng thc annrt!rc shaft,
thal revene currcnl flows th.ough th€ into or out of mesh with ihe ringgear
serics coil. and the magnetic fi€ld teeth. The over-running clurch is de-
builds up in fte direciion in whjch the sgned to transmit driving torque from
plunger nrovesbnck. As this happcns, the motor armature to rhe ring gear,
the resullant force of the ma-qnetic but pen it lhc pinion ro ovelrun the
fields in rhe shunt coil and rhe series a f m a t u r ea f t e r t h e e n g i n eh a ss r l r r e d .
EE-6
 EngineElectricalSystem
CONSTRUCTION

Magnelicswiich terminal

I 6 Piniol' u Shifl lever

2 Bneh t 2 M4neticswitchassembly
3 t3
t4
5 15
EE'63

FE.EE-10Erptodeduieuof ato'iingnotor

REMOVALAND 2, Loosennut used io securecon-

INSTALLATION nectingplste to magneticawitch"M"
Disconnectbatterygroundcable, terminal.R€movetwo scr€ws usedto
L
Dirconnectblack wire wiih yellow secwe magneticswitch, and remove
magneticswitchassembly.
tracerfrom magn€ticswitcht€rminal,
and black batterycablofrom battery
terminal of magjleticswitch.
2. Removetwo bolts securingstart"
ing motor to gear case,Pull starter
a$emblyforwardandrenovestarting
Fie. 8E.13 Renouing rcdr cov.r ond
3. lnstall startingmotor in reverse

DISASSEMBLY 4. Withdrawthe amature assembly

1. Remov€th€ brushcoverandtake and dift lever.
out thebrush.
/\
#
Fig- EE-12 Removingmogneticsaitch
ossemblr

td 3. Removetwo tbroughbolts and

then remove rcar cover and yoke
Fig.EE 11 n assemblyby lighdy tapping with a Fig. EE-i4 RemouingsnLlue
woodenmalletor plasticmallet. dwmblr .nd shift lerer
EE.1

5- Remove pinion stopper from
amature slaft end. To remove
stopper,Iirst, push the stopperto
clurch side. After removingstopper
clip, remov€stopp€r togethei with
over-ruruing clulch. Withdraw ov€F
running clutch assemblyfrom arma'
ture shalt.
Fis.EE-15 RenoulngooeHunni^8
clutcha$enbly
CLEANINGAI{D
II{SPECTION
Cleanall disassembledparts,but do
not use greasedissolving solventsfor
cleanlngover-running clutch,armature
assembly,magneticswitch assembly
and field coils llnce such a solv€nt
woulddhsolvegrease packedin clutch
mechanism andwoulddamage coilsor
oth€rinsulaiors,
Check them for excessivedamage
or weaf,andreplaceifflecesssry.
TERMI AL
Check terminal for damage and
wear,andreplaceifnec€ssary.
FIELD COIL
Checkfield coil for insulation.If
the insulationof coil is damagedor
worn,il shouldbe r€plac€d.
T..tlng fi.ld Goil for
conthuity:
Cornect tlle probe of a circuit
lester or an ohmmeterto field coil
positive(+) terminaland positive(+)
brushholder.
If testershowsno conduction,
iield
circuitor coil is open.
EngineElectricalSystem
Fig. EE-16 Conti.uity test of field coil
To.tlng ti.ld ooll tor Stound r
Place one probe of circuit tester
onlo yoke and the other onto field
coil lead(positiv€terminal).
If very litde resistance
is read,field
coilis ground€d.
EE170
!tE, LL-LI t'rou^o tesl ol letd cot
Flald coll t.rtcr for short!
Unsolderthe connecred portionof
each coil and proceedas mention€d
If a detectivecoil is found, it
stlouldbe replac€d.
BRUSHES AND BRUSH
LEADWIRE
Check the surface condition of
brushcontactandwearof brush.If a
loosecontactis found, it shouldbe
replaced.
If brush is wom and its lengthis
lessthan 9-5 nn (0.374in). r€place.
Checkthe connectionof leadclip
andleadwire.
Checkbrushholdersandspringclp
to s€ethat they are not d€formedor
bent, and will properlyhold brushes
against the commutator.
If brushes or brush holden are
dirty, theyshouldbe cl€aned.
EE.8
BRUSHSPRINGTEI{SIOI{
Check brush springtensionby a
springscaleas shownin FigureEE-18.
The readingshodd be 0.8 ks 0.81b).
Replacespdngif tensionis lowerthan
0.7kg (i.5lb). _
Fig,EE-18 Impectionof brurhsping
tentton
ARMAIURE ASSEMBLY
Checkexternalappearanc€
of arna.
tureandcommutator,
L M€asurearmaturestlaft fof bend
by a dial gauge.Replacearmature
shaft if the bend exceeds0.08 mn
(0.c031'n).
EEOl9
Fie.88.19 tnipectionof amatwe
Bhaftfot b.nd
2. lnspectcommutator.If the sur-
faceof commutatoris rough,it must
bc sanded lightly with a No.500
emery cloth. Commuiatormust be
ch€ckedalso for outof-round.If tl€
out4f-round is'more ttan 0.2 mm
(0.0079in), or ihe depthof insulating
mica is lcssthan 0.2 mn (0.0079in)
frcrn commulatorsurtace,commuta-
tor (arnalure)shouldbe turn€don a
lathe,so that the out-of-roundis less
tllan 0.05 rnm (0.0020in). Insulating
mica shouldalso be undercutso that
the depth of it is 0.5 to 0.8 rnm
(0.019? to 003ls in).
The wearhnit of commutatordi-
ameteris 2 mm (0.0787in). If com-
mutatoris beyondrepair,r€place.

- Note: It is recornrnendeilto rephce
commutator as an assemblyif wofn
or damag€d.
3. lnspecl solderedconnectionof
amature lead and comrnutator.If
loogeconn€ctionis found, soldertl
usinSrorlnflux,
4. Armaturetestfor ground
Usinga clrcuittester,placeonetest
probe onlo ,rmrture shaft and oth€r
onto eachcommutatorbar,
If tesler showsconductive,arma-
ture h gfoundedandmustbe replaced.
FE. EE-22 Amatute test forercund
5. Check armature for short by
placingit on armatufeterierGrowler)
with a piece of iron over armature
core, rotaiing armature.If the plate
vibmtes,armatureis shorted.
Engine Electrical$ystem
EE02O
Fie. EE-20 hlspectio| of commutatot
for out.of-tound
EE 0 2 1
Fig. EE-21 Uidercutting insuldting mico
EE023
FiE.EE-23 Armdhte test for
short cicuit
6. Check amature for continuity by
placing probes of tester on two seg_
menh side by side. If tesrer showsno
conduction,the circuil is open.
OVER.RUTI{Il{GCLUTCH
ASSEiIBLY
Inspect pinion ,isembly and screw
sleeve.Screwsle€vemust slidefreety
alongarmatur€shaft splines.If damage
is foud or resistanceis felt when
sliding,it must be repaired.Inspect
pinion teeth If excessive bbing is
found on teeth,it $ould be replaced.
Flywheel ring gear also must be in-
@@0
Fiet EE"24 O|ettunninA clutch
. ar3enbtr
BRUSI{ HOLDERTES'
FOR GROUI{D
Usinga circuittester,placeonetest
prooe onto negativesidebrushholder
and anotllet onto positive side. If
testershowsconduciiod,brushholder
h shortedto ground.Replacean insu-
latoror brushholder.
EE172
FiE.EE-26 Grou4.I test of brushhotdel
PII{IOI{ CA3E BEARIiG
IIIETAL
Inrpectbearing
metaifor wearor
side play. lf the cl€arancebetween
bearingmetal 0nd annstur€shaft is
morethan0.2 mm (0,0079in), replace
metal. Pressin a new bearingand
adjustthe cl€{nnce to 0.03 to 0.lO
nun (0.0012 to 0.0039 tn). Bearing
metalshouldbe pressed in so that th€
end of the bearingmetalis flushwith
IIIAGNETIC SWITCH
ASSEMBLY
Inspectmagnetic switchcontacts.
If
a rough welding is found on the
contact,it shouldbe repair€d.
ASSEMBLY
Reassemble startingmotor in re-
versesequence of disassembly.
wlen assenbling, be sureto apply
greaseto gear case and r€ar cover
bearingnetal, andapplyoil to pinion
sligltly.

TEST
PERFORMANCETEST
Startingmotof shouldbe subjected
to a "noload" lest wheneverit has
been overhauledto ensurcthat its
performance will be salisfactorywhen
installedon engine. Starting motor
shouldalsobe subjected to testwhen
the causc of abnornal operation is to
v.llN.1$
DIAGNOSES OF TEST
l. Low speedwith noload andhigh
currenadraw may resull from the
followinBcauses.
(l) Tisht,dirty or wom bcadrss.
(2) Bentarmalufeshafior loosened
fi€ldprobe.
(3) Shortedarmatur€;
Cheokarmatur€further.
(4) Aground€d armature or fieldl
a. R€moveinput terninal.
b. Raise two negativesidc brushes
from commutaior.
c. Using a circuil tcsle!, place one
pfobe onio input terminaland the
d. If testerindicatesconduction,rais€
the other 1wo brushesand check
field and armatureseparutely10
deierrninewhether field or arma-
tureis grounded.
EnginerElectricalSystem
be determined.A bri€f outline of th€ 3. Low current draw and low no'
test is givenbelow. load speedwould causehigh internal
resistance due to loose conneclions,
defectiveleads,dirty connutator and
tloJo.d teit
causeslistedon itern2-(3)-
. Connect stailing motof in series
with specified (12 volrs) battefy and
an ammeter capable of indicating
I ,000 amperes.
Specified current draw and revolu-
tion in this test is shown in
"speci-
MAGNETIC SWITCH
ASSEMBLY TEST
A ri'rrr
[ig. EE-27 Circuitofmagneticsuitch
osemblyt6t
li the slarting molor check is
"OK," checkmagneticswitchassem-
Fig.EE-26 No-loadt$l bly. Connoctcablesbctwe€n"nega-
live" battery terminaland starting
motor "M" terminal,"posiiive" bar
2. Failurcto opcralcwith highcuF
tery terminal!nd startingmotor "S"
renl draw nrayresullfrom the follow-
terninal conn€cling ignitionswitchin
ingilcms,
series asshownin FigureEE-27.
(l) A sroundedor open field coil:
Wiih ignilion switch on, measule
Inspcot thc connectionrnd lrrce
lhc gap '2" betweenpinion front
circuitby, circuilteslcr.
cdgeandpinionstopper-
(2) Aunaturecoil docsnot opcrale:
lnspect commutatorfor excessivc
burning.In thiscase.arcmay occuron
defectiveconnnulaiorwhen motor is ( 0 . 0 1 1t8o 0 . 0 5 9 i1n )
operatedwilh noload.
(3) Burnedoui comnutatorbar:
Wcakbrushspringtension,broken
brushspring,rubberbush,thfust oul
of mioa in commuiatoror a loose
contactbetweenbrushandcommula-
tor would causeburned-outcommutr-
FiE. EE-28 Medsuring gap "1. '
EE-10
 EngineElectrioatr
System
.SERVICEDATAATD SPECIFICATIONS
SERVICE EATA

BrushI€ngth
ftn (in)
W€arlimit mm(in)
6.s(0.256
in)
Brulhspringtension ks0b) 0.80.8)
Commutator

_ Outerdiarneter mrn(in)
Wearlimit tun (in)
Taperlimit nm Qn)
Depthof mica
Wear
limit rnrn(in)
0.2(0.0079)
Repairaccuracy nrn (in)
0.5to 0.8(o.Ol97
roO.O3l
S)
Clea$ncebetween
armaturo
rhsft andbearing
Wearlimit run (in)
0.2(O.OO79)
Ropaireccuracy mn (ln)
0.03to 0.1(0.0012
to O,OO3
Armatureshafidiameter
Pinionside nm (in)
l3 (0.s12)
Rearend rnm(in)
r r.5(0.453)
Wear
limit rnln(in)
0.1(0.003e)
Bendlimit mrn(in)
0.08(0.0031)
Capt.r" bctwe€nl,inionfront edle
andpinionstopper rnm(in)
1.5(0.0118to0

E€.l1
I--.;ji-
 EngineElectricatSystem
SPretFrcAflol{s . 1:1,

v l2
..................................-.........................,.....

l2
v .....................,....,..............................,.,,...,.
le$ than 60
morethrn7,000

0.9(6.5)
kFn (ft-lb) ....................................................

Magnetig
switch
h Sedos
coilr$lstsnce . ...... . 0.33[at20'C(68oF)
Shuntcoilrcsist.nc€ .......,.,.1.36lat 20oC(68oF)]

EE.12
 EngineElectricalSystem

TROUBLEDIAGNOSESAND CORRECTIONS

Condition Probablecause

Startingmotorwill not Chargeor replacebattery.

oP€rate. Defectivesolenoidswitch.
Looseterminalconnections.
Defectivebrulhes.
Defectivestartingmotor.
Repairor replacesotenoidswitah.
Cleanand tighien termin.l.
Replace
brushes.
Removestartingmotorandtest.

motor.
Noirystarting Looresecuring
bolt. Tightenbolt,
Wompiniongeal. plnlongear.
Replace
Poorlubricaiion. Add oil.
Disassemble
motor.
Wombrushes, brushes.
Replace

Starting
motor Disclurged
battery. Chargeor replace
battery.
slowly.
crenl<s Looseconnection
of terminal. Cleanandtightenterminal.
Wombrushes. Replaccbrush€s.
Lockedbiushes. lnspectbrushspringtenslonor rePa brush
holder,
Dirtyworncommutator, Cleanandreprir,
Armaturerubsfieldcoil. Replaceassembly.
Defective
solenoldswitch. Repairor replace
swltch.

Shrtingmotor Wornpinion plnion.

Replace
butdoesnot
operates Lockedpinionguide. pinionguide.
Repair
crankengine.
Wornringgear. Replace
ringgear.

motorwill not
Startin8 Defectivelolenoid switch. Repairor replacesolenoldswitch.
dk€ngageev€n Defectivegeart€eth. ReplacedefectiYegeor.
whenignltlonswitch
isturnedoff.

The chargingcircuit consistsof the
battery, alternator, regulator and
necessary wiring to connect these
parts. The puryoseof tlus systemis to
convert mechanical eneryy from the
engineinto elecirical €nergy which is
usedto operateall electricauy operat-
€d unitsand to k€eptle batteryiuly
cnaryeo.
When the ignition s'ivitch is set to
"ON," currentflowsfrom the battery
to groundthroughthe ignitionslvitch,
voliageregulatorIG terminal,primary
"P1," movable
side coniact point
contactpoint "P2," voltageregulator
"F" terminal,altenator"F" terminal,
"E" telminal,
field coil and alternator
as shownin Fture EE-29bY ful line
a[ow marks.Then the rotol in the
alternatoris excited. On the other
hand,currentflows ftom the batterY
to groundtfuoughthe ignitionswitch,
"L"
warninglamp, voltager€gulator
terminal, larnp side contact Point
"P4," movablecontact point "P5,"
andvoltageregulator"E" terminal,as
shown by dott€d line arrow marks.
l t -
EngineElectricalSystem
CHARGING
CIRCUIT
Then,the warninglamplights. "P2" is separatedfron the prirnary
side contact "P1" by the magnetic
. llhen the alternator begins to "VC2." Therefore,
operate,three-phase alternatingcur. forc€ of coil
"Rl"
rent is inducedin the staiorcoil. This rcgistor is appliedinto therolor
altematingcurrentis rectifiedby the circuitandoutputvoltageis decreased.
positiveand negativesilicon diodes. As the outputvoltageis decreased, the
"P2" and
The rectified direci curreni output movable contact point
reachesthe alternator"A" and .,E' primarysidecontact"P1" comesinto
contactonceagain,aod the altemator
On the other hand, the neutral voltage increases.Thus, the rapid
point voltagereaches"N" and "E" vibntion ofthe movablecontactpoint
"P2," maintainsan alternatoroutput
telminals(nearlya half of th€ output
voltage), and cunent flows from
voltageregulator"N" t€rminnlto "E ' Whenthe alternalorspeedis furthel
.ermjnal or ground throughthe coii increased or the voltagestarts1o rise
"VCl" as lhown in
FigureEE-30by €xcessively,the movablecontactpoint
"P2" comes into contact
the dottedlinearrowmarks.Then,ihe with
coil "VCl" is excited, and the secondarysid€ contact point "P3."
movablecontact point "P5" comes Then,the rotor currenlis shutoff and
into contrct 'rith vollagewindingside alternatoroutput voltageis d€cr€ased
contactpoint '?6," Thisactioncauses immediately.This action causesio
io turn off th€ warninglump and separatemovabl€contaci "P2" from
compleiethe voltagewindingcircuit, secondarycontact "P3." Thus, the
asshownby the full linearrowmlrks. rapidvibrationof the movableconlact
When ihe alternatorspeedis in. point "P2" or bleaking and com-
deasedor the voliagestarls to rise plelingthe rotor circuit maintainsan
excessiv€ly, the movablecontacipoinl altematoroutputvoltageconstant.
I E
-l
ii
I"
I
I
i
Fie. EE-29 Chdteinscncuit (I)
EE-I4
 EngineElectricalSystem

_l
l-_----_--_-- lgnition sq

Almaturc
= Battery
T
.E.i

L_____-
-____- -i
F.A
rt:
I
Altolnator

I,ig. EE-30 Chdrsits circuit (n)

ALTERNATOR

CONTENTS
DESCF IPTION EE,15 T N S P E C T TOOcN B R U S H.............
REI\4OVAL AND INSTALLATION EE.16 SPRINGPRESSURE TEST. . . . . . . . . . . . . . . . EE , ] 9
D'SASSEIVIBLY . ,,,, E E .6] ASSE[,481V ........... E E .9]
]NSOECTIO AN D B E P A I R EE.17 A L T E R N A TTOEFS T , , . . , . . , , , . , . . . . EE.19
F O T O BI N S P E C T T O N EE.17 SERVICEDATA AND SPECIFICATIONS EE.21
TNSPECTTON OF STATOB. . . . . . . . . . . . EE.18 SERVICEDATA
INSPECTIO ONF D i O D E 8E.18 S P E CI C
F ATIONS EE21

DESCRIPTION like a one-wayvalvefor electricityso

that chargingcunentpasses easilybur
reve$e curent h shut out. In this
Alternator Applied engine tlternator, six diodes (lhree negative
and three positive), are installed in
LTt35-13B J13,Jl5 andJ16 positive and negativepiates as an
asernbly.
LTr5045 Jl3, Jls andJ16(Option) Packlypesilicondiodesareusedin
this aliernato..Thes€diodesare di-
rectsolderedat their tips, and con-
structed *ith positive and negative
In the alternator,
a magnetic Iieldis smallfi€ld curent- Output currentis conjunction. They aremountedon the
producedby the rotor which consists generatedin the amatur€ coilslocated iwo plates which combhe the func,
of alternatorshaft, field coil, pole in the. stator- The stator has ihree tion of heatdissipating plafeandposi.
pieces, and slip rings, The slip .in8s windings and Seneratesthree.phase tive/negaliveterminalsand are light in
pr€ssedin the shaft conduct or y a alternatiogcurrent.Silicondiodesact w€ighlandeasyto service.
EE.15
 EngineElectricalSystem

o
oo@

I
t

r@o@
2
l

r--------------
0tr --J t0
I
7
8
9 Diode serplale asenbly

@ .."",
FE. EE-31 Etploded uieu of altendtor

DISASSEMBLY
L Removepulley nut, pulley rim,

I
-D!U^ I
@ffi
@oo
I
2
3 FiE-EE33 RemouinEpuller and fan

Fig. EE'32 Sectiotul Dieb of altenatol

REMOVALAl{D 2. Rernove brush holder fixinS

INSTALUTTION
l- Disconnect negativebattery ter-
minal.
2- Disconnect two lead wires and
connectorfrom alternator.
3. Loosenadjustingbolt.
4. Removealternatordrivebelt.
5- RemoYeparts associatedwith
alternalorfrom engin€.
6. Rernovealtemato.from vehicle.
7. Installaliernatorin reve6€order
EE.16
scr€ws, and remove brush holder
cover.Removebrushholder forward,
and remove brusheslogelh€r with
brustrhotder.
Note: Do not disconnect"N" termi
nal fron stator coil l€adwire.

I
II
I
I Fig-EE'34 Remouing
brush
3. Loosen and remov€ throu8h
bolts.Separatefront coverwirh rotor
from rear coverwith statorby lightly
tappingfront bracketwith a wooden
mallet.
o!@:ir*l
Fig. EEAS Sepatutingfront cover
uith rotor frcm rcar couer
4. Removethree se1 scrcwsfrom
bearingretainer,and separateroior
from front cover.
! @@
rig. EE-36 Remoui/tgrotor
5. Pull out rea. bearingfrom roror
assemblywith a press or bearing
puller.
Engine ElectricalSystem
Fig. EE 37 Pulling out of rcar
Fie. EE-4o Inspectinsaltemator
ROIOR I]{SPECT|O
Iig. EE'38 Pullingout of rcar
bedrins(II) 1. Conduction lestof rotorcoil
Apply teslerbetw€enslip ringsof
6- Renrovedjodecov€rfixiogscrew,
rotor as shown in Figurc 8E.41. lf
and removediode cover.Disconncct
threestatorcoil leadwiresfrom diode thefe is no conduction,discontinuity
terminalwith a soldering of fieldcoil mayexist.Whenreshtance
iron.
7. Remove"A" terminalnut and h approximalely 4.4O at normalambi-
diode installalion nut, and femove ent lemperature, conditionis $tk,
diodeassembly. factory.
O
lr
f\ ,, }ir, 4\^u, )r
\J I 'r l.!'
"':q f " ,,'
I Djodc a$ehbly
2 Diode cover
Iig. EE-41 Conductiont6t of
Fig. EE-39 RemouinEdiode Nembly
rotor coil
Not€: Use c,5rein handling diode as-
s€mbly to prevent an undue stress
2. Ground lesl ofrolor coil
Check conduclion betweenslip ring
and rotor core. If conduction exish,
INSPECTIOI{AI{D replace rolor ass€rnbly,becausefield
REPAIR coil or slip ring rnay be gfounded.
Removeattematorfrom vehicleand
apply lester between lead wire F
(whitewith blacklracer)andleadwire
E (blackcolot.
Whenthe resistance is approximate-
ly 5s,,the conditionofbrushandfield
coil is satisfactory-
Whenno conduc
tion existsin brush or field coil, or
whenresistance diff€rsrcmarkabtybe
tween those parts. disassenbleand Fig. EE 42 Testinqrotor coit for
grcund
EE.]7

INSPECTIOIIOF SIATOR
l. Conduclion test
Stalor is normal when ther€ is
conduction between individual stator
coil terminals. When there is no con-
duction between individual terminals,
cableis broken.
Replacewith stator assembly.
FiE.EE-43 Testingstatorfor
conduction
2. Groundtest
If eschleadwire of armaturecoil
(includingneutralwirc) is no! conduc-
tive with stutol corc, condition is
{ie.EE 45 ConductiDe.lir.ctio^ af.Iio.te
Diodeinstalledon O plate is a posi-
tive diode which alows currenlflow-
ing from terminalto @ plale only.In
other words, curreni does not flow
from G) plateto tenninal.
EngineElectricalSystem
saiisfactory.Il there i3 conduction
stato.coil is grounded.
Fig.EE'.14 Testitrgstator for
Eround
INSPEC'ION OF DIODE
Pefform a conduction lest on
diod€s in both direclions,using an
ohmmeter.A totil of six diodesare
used;threeare mountedon th€ posi-
tiv€ O plste, and other threeare on
ihc negativeO plate.The conducijon
lest should be performedon each
diod€,betweenlhe teminnl andplate.
(
Fig. EE 16 tnspectin' needti@ dio.te
EE.I8
Diode installedon O plate is a
negalivediode which alows cu(eni
flowing from O Plale to terminal
only. In olher wods, currentdoesnot
flow from termiralto O plate.
dio.le
FE EA47 ln|pe.tne negatiDe
If cuncnt flows towardboth posi-
tive rnd negativedirections,diodc is
lf 0urron!flowsin the
short.circuited.
samedhectiononly, diodc is in good
condilion.If ihereis a defectivediode,
rcplaceall diodesGix diod€t as an
ass€mbly.(See below table.) Th€se
diodesafeunsewiceable.

Testprobeofa circuittester
o o
O plate
terminal
O plate
O plat€
@ plate
I]{SPECTIONOF BRUSH
Check movemenlof brush and if
movementis unsmoolh,checkbrush
holderandcleanit.
Checkbrushfor wear.If it is worn
SPRIIIG PRESSURETEST
With brushproj€ct€dapproximai€-
ly 2 mm (0.078? in) from brusl'
holder,measurebrush springpressure
by the use of a springbalance.Nor.
mally, the rated pressureof a new
brush springis 255 to 34s g (9.0 to
12.2 oz).
Moreover,when brush is worn,
pressure d€creases
approxinately209
(0.7oz) p€r l mm (0.0394in)wear.
Fie. EE 50 Meosurina slnng Praure
EngineElectricalSystem
Conduction
G) plate o
terminal
O plate
terminal o
O plate o
O plate
Fig.EE-48 lnspectingdiode6
down to Iessthan the specifi€dlimit, rnsulatin8bush 4 Sratorcoil leadwirc
replace
brushassembly. Redi cover 5 A tqhinat bolt
Diodeasonbly 6 Diodecovcr
Checkbrush pig tail and,if found
defective,
replace. Fie.EE-61Sectionot
oieu of diode
o\d A terminol
3. Tightenpulley nur with tighien-
ing torqueof 350 ro 400 kg-cm(301
to 344 inlb), Whenpulley is tighn
ened, make lure that deflectionof
V.groove h lessthan0.3 mm (0.01l8
n,r,
Fie.5E-49 Brwh uear limit
ASSEMBLY
Reassemblealternatorin ihe reverse
sequence
of disassemblynotingfollow-
mgmarrcrs:
Fie. EE-52 Tiehteningpulley nut
l. When solderingeachstaior coil
Ieadwire to diodeassembly rerminal,
carry out the operationas fast as
possible.
2. Wheninstallingdiode"A" termi"
nal, insta insulatingbush and insu- ALTERNATORTEST
latingtub€corectly. Before conducting an alternatoi
test,make surel}Iar the baitery is fully
charged-
To conduct a test, it i! n€cessary to
use a 3o-volt voltneter and suitable
Set up a test circuit as shown in
Figure EE-53 and tesr alrernarorin the
manner indicated in th€ flow chart
EE.I9
 Engine ElectricalSystem

l. Disconnectconnectonat altemator-
2. Connectonetestprobefrom voltmeterpositiveterminalto "N" terminaloi "BAT" terminal.Connectt}Ieother
testprobetoground.Makesurethat voltneterregisters batteryvoltage.
3. Tum on headlights
andswitchto MainBeam.
4. Startengine.
5. Increase
enginespeedgraduallyuntil it is approximately
I ,l 00 rpm,andtaketh€ voltmeterreading.

Measured value:Below12.5volts Measuredvalue:Over12.5volts

Altemator is defective.Removeand checkit Alternatoris in goodcodition.
for colldiiion.

a. Do not run engin€at more than

1,100rpn rvhiletestis beingcon-
duct€donaitemator.
b. Do not raceengine.

?iE. EE-63 T6tin9 altemdtor

EE.20
 EngineElectricalSystem

SERVIGE DATA A]{D SPECIFICATIONS

SERVICE DATA
- LTIJ5.t3B,LTl50-05>

Statorcoil
Resistaftep€r a phase 0.17lat 20oc(58oF)]
Rotorcoil
Registance 4.4 [at20oc(68eF)]
Brustl
Br:ush
length 14.5(0.571)
Wearlimit 1(0.27s6)
Springpressure 0.25to 0.35
(0.5sto 0.7?)
Slipring
Outerdfumeter 31(t.220)
Reduction
limit l (0.0394)
Repairaccuracy 0.05(0.0197)

SPECIFICAT|Ol{3

Item LT135.l3B LT150-05(Option)

Make HITACHI HITACHI

Nominalriting l2v-35A t 2v-50A
Groundpola.ity Negatlve Nogativ€
Revolution 1,000
to 13,500rpm I ,000to 13,500
rpm
Minimum revolution underno load LessthanI ,000rpn L€ssthanI ,000rpm
Outputcurreni 284 (14V,2,500rym) 37.5A(14V,2,500rpm)
Pulley ratio 2.25 2.25
Appliedregulatormodel TLtZ-61 TL\Z4l
 EngineElectricalSystem

REGULATOR

CONTENTS
D F S ' RP T I O N .. EE.22 C I A R G I N BCF L A Y , , ,
MEASUREMENT OF REGULATOR S F V ' E D A T AA N D S P I C| I C A T I O N S, . EE 26
VOI TACt EE23 T R O U E L ED I A G N O S EASN D
ADJUSTIVTNT EE.24 C O F c - C T I O \(S1 l d 1 9 " I e r . d r o .r .' . . . . . . . EE27
V O L T A CR| I - C U I A T O
. .B
...........

DESCRIPTION
The regulatorconskisbasicaliyofa
voltageregulatorand a chargerelay.
The voltaSeregulatorhas two setsof
contactpoinls,a lowef sel and upper
rct, to control alternatorvoltage,An
armatureplateplacodbc|weenthe two
lets of conlacts,noves upward or
downwardor vibrales,The lowercon-
tacts,whenclosed,completethe field
cirouitdifect to ground:andthc uppel
conlacts,when closed,completethe
field circuitto groundthrougha resh!
ance(field coil), andproducesalterna.
IOf OUIpUL
The chargerelay is similarin con-
structionto thevoltageregulator.
Whenthe uppercontactsarcclosed,
ignilionwarninglampgoeson. 2

EE146
Regulatofmodel Appltcdengjn€ Appliedaliernator
Fig. EE-54 Vietr ofrcmovins couer

TLt2.6) J l 3 ,J l 5 a n dJ 1 6 LTt35.l38
As for construction, the voltage
LTl50-05 (Option)
regulalor is very similar to the charge
relayasshownin Figure8E.55.

10
ll 2
l2 l 12 Co
l 3 3 m n ( 0 , 1 1 8 1 i nd)i a .
l3 5
6 t 4 4 m m ( 0 . 1 5 7 5i i ) d i a .
l4 1
l5 8
9 VoltJgeregulatorconlact
(b) Co$truction of chaqe rclay
(a) construction of uoltagerecutotor
Fig. EE 55 Stuctutol uieu of rclay

EE.22
 Engine ElectricalSystem
.MEASUREMENT
OF REGULATOR
VOLTAGE

Regulatorvoltageis measured with

regulatorassembled with altemator.
Whenmeasuringvoltagewith regulator
mountedon vel cle,it is necessary to
Shortcircuitlere (letween
rotateengineat highspeed. fus iide lerminaland(-)
Connect DC voltmeter(15-30V), t€ininalof anmebt befit€
DC ammeter(15-30A),battery and
resfutor(0.25f,,) witll cablesasshown.
1. Checkto be surethat all electrical
Ioadssuchaslamps,cooler,radio,etc.
aredhcoftrected.
2. Beforestartingenginejbe sureto
(10A) (30v)
make short circult with a cablebe-
tween fuse side terminal of resistor
(0.25Q)and negative EEO55
sideterminalof
amneter.Failureio follow this cau- ti9. EE-66 Meatutingrceulatoruoltogeuith regulatoron uehicb
tion cauresneedle of ammeterto
swingviolentlyandreversely, rcsulting 3. Refer the following chan to partsarein gooalcondition:
in a damaged ammeter. determineif regulator and relaiive

l. Startengine,
2. Rotateengineat 2,500rpm for several
minutes.

After racingfor severalminuies,ammeterreading After racing for severalminuteg,ammeter

- below5A. reading- over5A.

Fully charged
batteryavailable. Fully charged
batt€rynot available.
L R€place'rvithfully chargedbattery. l. Connecta 0.25Qresistorin series.
2. Ch€ctto seeifcurrent fallsb€low54.

Curcnt falh below5A. Currentdocsnot fall below5A.

Recha'ge
bdtre'yandseeifcuflenrfailsbelow5A.

Reduceenginespeedto idling and then raiseit to 2,500 rpm while observingneedleof voltmeler.

Needle ol voltmeter held within lirnits shown in the iable Needleofvoltmeterout of limitsshownin the
followinBchart.
Regulatorfunctionhgproperly. ReSulatorout of order. Haveil repaireda!

ADJUSTMENT
VOLIAGE REGULAIOR
As the resultof aboYeneasure-
ment,whenregulating voltaged€viates
ftom ratedvalu€,adjustregulatorin
accordancewith the followinginstruc-
l. lnspect contact surface,and if
rough, lightly polish surfacewith fine
emerypaper(#500or 600).
2. Measureeach!ap, and adjustif
necessary. Adjust coregap analPoint
gap in that order.No adjustmentis
requiredfor yoke gap.
3. Adjustingcoregap
Loosenscr€lr [a mm (0.15?5in)
diameter] which is us€d to secure
contactseton yoke,andmovecontact
upward or downwardproperly. S€e
FigureEE.57.
2 screw,Turn this screwclockwiseto
3 4 mm (0.1575h) dh. scles
Ctossh€adsqewdrivo! EEo66
Fi'.8E.57 Adjwting core$ap
Engine ElectricalSystem
4. Adjustingpoint gap
Loosenscrew [3 mm (0.1181in)
dian€terl used to secureuppercon-
tact, and moveuppercontactupward
or downwardadequately. SeeFigure
EE,58.
I
2
3
Fi8- EE-59 AdjBting requlotineuoltoge
1
2 3 m n ( 0 . 1 l 8 li r ) d i r . 6 c r o w
3
UDDe! contart
Fig. EE-58 Atljusting point gdp
5. Adjustingvoltage CI{ARGII{GRELAY
Adjust regulatingvoltage as fol-
Normalr€layoperatingvoltaSeh 8
Loosenlock nut securingadjusting to 10V asmeasured at alternator"A"
terminal. Relay itself, however,op.
incresse,or counierclockwiseto de. eratesat 4 to 5V.
crease,regulatingvoltage.SeeFigure Use a DC voltmeter,and set up a
EE.59, circuitasshownin FigureEE-60.
EE.24
 EngineElectricalSystem

l. Connect positiveterminal of voltmeter to regutatorlearl conn€ctor..N,,

lerminal with negativeterminal
gromded.
2. Start engineandkeepit idle.
3. Takevoltmeter r€ading.

0 Volt B€lolr5.2 Volts Ov€r5.2Volts

1. Checkfor continuitybetlveen (Pilot lamp remainslit) (Pilotlarnpremains
"N" teminals lit)
of regulatorard l. Ch€ckfan belt tension. Pilot lamp relay coil ot contact
altornatot, 2, If conect, remove regulator pointsout of ord€r.
2. Alternatot circuit dofectlve if andadju8tasnecesssry. Replace regulator.
continuity exirts.

Over5.2Volts
(Pilotlempdoesnot light.)
PilotIamprelayossembly
ia in goodcondition,

L (WR) IG (WL)
F(WB)

E (B)

fig. EE40 T$trng chaEingrcW

t *
EngineElectricalSystem

SERVICE DATA AND SPECIFICATIONS

Voltag€regulator
Mod€l 'tLtz4l

Regulatingvoltage
(with fuly chargedbattery) V 13.8to 14.8
Voltagecoil resistance O 10.3lat 20oc (68"F)]
Rotor coil insertingresistance O 10
Voltageco_ilseriesr€sistance O
Smoothingresistance O 4l
Corcgap
Pointgap
Charge
rclay
Releasevoltag€ V 8 1ol0 at "A" terminal
Voltagecoil rclistrnce O 3l .9 lai 20oC(68oF)]
Coregap n.'Jn(in) 0,8to 1.0(0.0315 to 0.0394)
Pointgap mm (in) 0.4100.6(0.015? to 0.0236)

EE.26
 Engine ElectricalSystem

TROUBLE DIAGNOSESAND CORREGTIONS(lncludingalternator)

Condition

No output Stickingbrushes. Corr€ctor replacebrushes

andbrushsprings.
Dirty brushes
andsliprings. Clean.
LooseconnectioNor brokenleads. Retightenor solderconnections.
Replaceleadsif necessary.
Openstatorwinding. Repairor replacestator.
Openrotor winding. R€place
rotor.
Opendiodes. Replace
diodes.
shortedrotot. Replace
rotor.
Shortedstator. Repa or replacestator,
Crounded"BAT" terminsl. Replace
lnsulator.
Brokenfsn belt. Replace
belt.

Excessive
output Brokenneutralwire(colorofwtre tNwhite.) R€place
wire.
Defective
voltageregulator. Check regulator of'eratlon and repair or
rcplaceasrequired.
Poor gioundingof alternatorand voltage Retightentermlnalconnection.
regulator"E" terminol,
wire (coloror wire h black.).
Brokenground Replace
wire.

Low output l-oos€

or womfanbelt. Retight€nor replacebelt.
Sticking
brushes. Correct or replacebrushesand springsif
necessary.
Lowbrushspringiension. Replace
brushspringr.
Delective
voltage
regulator. Check regulatorop€rationand repalr or
rcplaceasrequired.
Dirtysliprings. Clean.
Psrtialshort,gound, or open in stator R€place
stator.
Mnding.
shodedor grounded
Partially rotorwinding. Replace
rotor.
Openor defectivediode. Replace
diod€.

Noisyalternator Loor. mountinS. Retightennountingbolh.

Loosedrive pulley. R€tighten
pulleycorr€ctly.
Defeciivebal beariry. Replace
bearing.
brushes.
Improperlyseated Seatbrushes
correctly.

EE.21
 Engine ElectricalSystem

DISTRIBUTOR
CONTENTS
rB .c ro\
coNS EE.28 A D V A N C E I T l E C HNA r s t !.1. .s. . . . . . . . . . . . EE,3O
.
C N T T K \ CA N DA D I U S T V | N
......... EE.29 D I S A S S E I V ] B LAYN D A S S E I / ] .B. L . .Y. . . . . . . .
c A PA \ D C O OP q c A D .......... EE29 D SASSEMBLY EE.31
POt\T .......... EE.29 A S S E M B .L.Y. . . . . . . . . . . . . . __ . . . . . . . . . . . E E3 2
c o N D\ r' r q EE30 S E F VC E D A T AA N D S P E C I F I C O AT N S . . . . . E E3 3

CONSTRUCTION
The distributorconsistsol breaker
Distributor lnodel Applied engine plate wilh contacipoints,centrilugrl
advance mechanism,vacuum unit,
D4l l-68 drive shaft. and rotor. Figure EE-61
and 62 showa seclionalview of the
D4t3-84
unit.
D4l1.81 J15

I
2
l

8
9

Fig. EE 61 Constructian
 Engine Electrical System

I
6
t

ll Lcodwirea3smbly
l2 Roto!ttead.lsenbly
13 Cond.nsia$embly
l4 Tcrninalasrnbly
15 Yacuuncontrolarsembly
16 Capa!!€trbly
l? Calbonpoiitassehbly
8 BF.ker plalc asmbly
19 Oring
10 Edth vLe as!.,nbly

FE. EE-62 Conponenttof .Jbtributot

CHECKINGAND
ADJUSTMEl{T
CAP AI{D ROTOR HEAD
Cap and rotor head must be in-
spected at r€8ular intervals. Every
5P00 km (3,000miles)of operstion,
remove cap and clean all dusi and
carbond€positsfrom capandrotor.If
cap is crack€d or is leating, replace
POITI
Standardpoint gapi! 0.45 to 0.55 paper (No.500 or 600) or with oil
nn (00177 to O-O2t7in). In casesize
is off the standaid,ad.iustmertis made At t}Iistime,greasemustb€applied
by looseningpoint screws.Gtp gauge to camshaftheadand camheel.
is requircdfor adjustment. When wear on breaker points is
Point gap must be checked every noticeable, replace points together
sp00 kln (3,000niles) of operation. with conlact arm. To replac€,proceed
When point surfaceis rough, take
off any irr€sularities with fine sand-
EE.29
 Engine ElectricalSystem

F
fig. EE-65 Disosemblinscontdct
arn dad contactPoinl
3 Prnnalylcadtcrminrl

point gaP
Fig.EE-64 Madsuting
First turn out sel screwsI to 1,5
lurnsat conlactarmandprnnary lead
Fig, EE'63 Breaher
wireconnectionjusl farenough
to full
out prinary leadteaninal.
Ref€ningto Figrre1.i1.63,
unscrcw
two contact sct lixnrg screwsand
While holdirrgcontactrnn by iin-
gers,pu]l out contactseltowardyou
by raisinSit slightly.Contrct point
and alm can lhen be rcmovedt0-
gelher.
Installnew contactponrtrnd anrl
assemblyin rcverscsequ€nceof r€-
moval.Coatcrnr hccl andcamshaft
headwilh a lightcoating
ofgrc sc.
CONDENSER
Satisfactoryperformanc€of con-
denserdcpends oo capacityanddegree
of insulation,requiringatt€ntionto be
sure that terminalsare cl€anand set
Chccking ofcondenser ismad€by a
capa.itytester.Thk canalsobe made
by n circuit testerwith its rangcsstto
high reshlancereirding.Wh€nneedle
of tester swingsviol€ntly and then
movesback to infinite gradually,it is
an indicationthat condensor is in good
If n€€dlcshows ny steadyrcading
or if it regist€rs
zero,the likelihoodis
that translbrmeris out of order,call-
ingfor replacemenl.

ADVANCE MECHANISM

<Pe.fo,rnances>

2A

2050x1
9
2050x1
Bro
5 205(Jx?. .l:

0
65{t;2.1
J1 t?st6,,,
500 1000 1500 2000 2500 1000 0 150 200 250 300 350 ,1110
Distribniorrolriion Gpr) VacuunGrnHg)

Fie. rF.66 Pcr[armon.ectru. lor Mo.lel Dd I I 6A

EE.30
 Engine ElectricalSystem

3 1 0 310

1000 1500 2000 2500 100 150 200 250 300 350
(rpnt
rotation
Distribulor vacuumCmmHg) E E1 7 5
Fig. EE'67 P.tfotnance cutuefot Mo.tel D413.84

810 310

1000 1s00 2000 2500 r0o 150 200 250 300 350
(ryn)
Diltibrto!roldtion VacuumCnnHs)

Fie.EE-68Petormdnce.utuefor ModelD4| I-81

<Vacuum sdvancemechanism <Centrifugaladvance DISASSEMBLYAND

parts>
mechanical
If vacuumodvanc€mechanism failg
to operateproperly, check for the
followingitemsand correctth€ trou-
ble asreq ired.
l. Check vacuumifllet for signsof
leakage If necessary,
at its connection.
retightenor replacewith a newone.
2. Checkvacuumdiaphragmfor air
leak.
If leakis found,replacediaphragm
3. Inspectbreakerplaaefor smooth
If plate doesnot movesmoothly,
this condition could be due to sticky
steel bslls or pivot. Apply greas€to
steel balls or, if necessary, replace
breakerplateasan assenbly.
parts>
rnechanicai ASSEMBLY
When causeof enginetlouble is
tracedto centrifugal advance m€chani-
DISASSEIIIELY
cal part,us€dhtributortesterto check
its characteristic. follow the proce-
To disassemble,
$,hen nothinS is wrong with its
characteristic,conc€ivable causesare l. Takeoff capanddisconnect
rotor
def€ctiveness or abnormalwearing-out
of driviflSpartor otherpart. 2, Removevacuumcontroller,
Do not disass€mble it. In cas€of
impropercharacteristic, removeon-off
switch part and check closelycam
assembly, govemorweight.shaft and
Sovernor sprng.elc.
Whencentrifugal advance mechani-
cal part is reassembled, be sure to
check advancecharacteristic by dis' d
d
Fie. EE 69 Dins@mblirq odcuud
contrcUer

EE31
 EngineElectricalSystem

3. Rlmovecontactbreaker. 6. mrcn caln is to be removed,first ASSEMBLY

Referto PageEE,30,whencontact remove set scrcw since shalt head is Assemblycan be made in reverse
fasten€dby the screwto hold cam
sequenceof disassembly.Refer to
down.Put natch markacrosscamand

s
Figurc 8E,75 for replacementand
t shaftso that originalcombinationcan reassemblyof govemor spring and
be restoredat assembly.
7. Whengovernorweightand spring
are disconnected, be car€fulnot to
stretchor deformgovernorsping.
applygrease
After disassembling, to
governorweights.

Fig.88.70 Renoving contact set

Fi|- EE-74 Renouing con

Fig.88.71 Renovingcontdctbrcaker

4. When contact br€aket is disas-

sembled,be cafefulnot to lose steel
balls between breaker sprtng and
plate.
brea.ker
5. Pull knock pin out and dhcon-
necl collar to removethe entire ro-
talng Frts-

' I2
8 Govenorspins{A)
3 9 Rotorpositio.inglip
FA. EE-72 Remouingknochpia
5
Fig. EE-75 Settinggouemorspringand @m

Fig.EE-73 Renodag rototioh parts

EE.32
 EngineElectricalSystem

SERVICE DATA AND SPECIFICATIONS

SERVICE DATA

< All distributofs>

Pointgap rnm(in) 0.45to 0.s5(0.0177to 0.0217)

kc 0b) 0.s0to 0.65(1.10to 1.43)
shaft dia'neter(lowerpart) rnm(in) 12.430to 12.440(0.4894 to 0.4898)
Housinginnerdiameter nm (in) 12.450to 12.468(0.4902 to 0.4909)
Clearanceb€tweenshaft andhousing nnr'(in) 0.010to 0.038(0.0004 to 0.0015)
Repairlirnit of clearance mm(in) 0.08(0.0031)

Shaftdiameter(upp€rpart) nJn (in) x- :9-!9! ,6 -- -9!!9?1

--,,.6 -0.0006
0_014
CaIninnerdiameter mm(in) 8.000to 8.015(0.3150
to 0.3156)
Clearance
beiweenshaftandcam mrn(in) 0.005to 0.029(0.0002
to 0.0011)
Weightpivot diameter mm(in) (0
4.972to 4.990 ,1959to 0.1965)
Weightholedianeter mm(in) 5.000to 5,018(0.1969
to 0.19?6)
betweenpivot andhole
Clearance mm(in) 0.01to 0,046(0.0004
to 0.0018)

SPECIFICATION3
Distributortype D411.68 D4r3-84 D{ I l.8l

Make HITACHI HITACHI HITACHI

Appli€dengine Jl3 Jl5 Jt6
Firingorder 1-3-4-2 1"3.4.2 1.34.2
Rotatingdirection Counterclockwis€ Counierclockwise
Ignitiontiming(B.T.D.C.) degree-rpm 80/600 8'/600 8o/600
Dwell angle degre€ 49o to 55o 49oto 55o 49oto 550
Condenser
capacity !F 0.2OIo 0.24 0.20to 0.24 0.20to 0.24

EE.33
 EngineElectricalSystem

COIL
IGNITION

The ignition coil is of an oil-filied

type. The ignition coil caseis filled
with oil whichhasgoodinsulating and
heatradiating characteristics-
High sparkingvoltageis produced
from startingto enginehighrevolution
by the exlernalresistorwhich is used
in the ignitioncoil cncuit for 6R'200.
(Extefnalresistorb not equippedfor
C1Z-200.)The internalresistorlimih
to a maximumsafeflow ofthe prirna-
ry currertthroughthe coil anddistrib-
utor contactpoints.Thus,it pfotects
the contactpointsduringslow speed
operationwhen th€y ar€ closedfof
longintervals. 2 Se.ondary
teiminal
3 Cap
4 Spring

10 Seg'nen1
ll Casc

FE. EE.76 Construction

SPECtFtCATtOttS
Makeandtype...............-. HTTACHI(6R.200) HITACHI(cr2-200)
Prinaryvoltage v ......................_....._........................
12 12
Sparkgap nn (jn) ..........................
. .. .. . ......Morcthan? (0.2756) Morethan7 (0.2756)
Primaryresislance
at 20oC(68oF) o ...................................................
1 . 5t o 1 . 7 4.2It)3.4
Secondary
resistance
at 20"C(68oF) KO 9-5lo l l.6 9tol1
Externalresistor O ..........-..-..................-....................
t.6

8E,34
 EngineElectricalSystem

SPARKPLUG

CONTENTS

D E S CPRT I O N .,..... EE,35 SERVICE D A T A A N D S P E C IC

F A T I O N S. . . . , E E . 3 6
NSPECTION ........ EE-35 TROUBLE D I A G N O S EASN D
N D B E G A PNPG . . . . , , , , , . . . . . E E . 3 5
C L E A N I NAG C O R R E COTN S -...., EE'36

DESCRIPTION Overhealing:Whiteor light grayinsu- spafk plugs,low fuel pump pres-

The sparkplugsare of the resistel lalor with black or gray brown sure, wrong selectionof fuel, a
typ€.having14 mm (0.551in) threads spots and bluis,hburnt electrodes hotterrangeplug,€lc.
and0.8 to 0.9 nm (0.031to 0.035tn) indicat€engineoverheating. More- to replacewith plugs
It is advisable
grp. Insp€ctionandcleaning shouldbe over, the appeuanceresultsfrom havingcolderheatrange.
rnadeerery 10,000km (6,000miles), incorrect ignition timing, loose
and replacement shouldbe carriedout
.vcry 20,(Imkrn ( l2,000milet,
Note: A[ sFrft phgs install€d on an
eo8ine,must ba of the samebrand
atrdheat nog€.

l1{sPECTtOl{
l. Removesparkplug wire by pull.
ingon boot, not on wir€ itrelf,
2. Remov€sparkplugs.
3. Ch€ck electrode!and inner and
outer porcelainsof plugs,noting the
type of depositsand the degreeof
€lectrodeerosion.Referto FigureEE-
77.
Lifc
Normal: Brown to grayish{an de.
posih afld slight electrodewear E€079
indicate correct spark plug heat Fie. EE-77 Spothplug
nnge.
Caronfouled: Dry fluffy carbonde- 4. Afl€r cleaning,dresselectfodes type cleaner.Avoid €xcessiveblasting.
positson the insulatorand elec- with a smaufine file to flatlcn ule Clean ard remove carbon oi oxide
trode are mostly causedby slow surfacesof both centerand sideelec- deposih, but do not wear away porce-
speeddrivingin city, weakignition, trodesin parallel.Setsparkpluggapto lain. If deposiis are too stubborn,
too rich fuel mixture, dirty air specification. discardplugs.
cleaner,etc. 5. Instal spark plugs and torque After cl€aning spark plugs, renew
to replacewith pluSs
It is advisable ezchplugto 1.5to 20 kg,m(l t to 14 fir'ns surface of electrodeswith file
havinghotterheatrange. fl,rb). mentioned above. Th€n gap spark
Oil fouled: Wet black depositsshow 6. Connectsparkplugwires. plugs to 0.8 io 0.9 mm (0.031 to
excessive oil enlranceinto conbus- 0.03s in) using a round wire feeler
tion chamber through worn rings gauge. A[ spark plugs new or used
and pistons or excessiveclearance should have the gap rhecked and reset
betweenvalveguidesand stems.If
CLEANINGAND by bendinggmund electrode.
the samecondition renainsafter REGAPPING
repair,usea hotterplug- Cleansparkplugsin a sandblast
EE.35
 EngineElectricalSystem

fie. EE-78 Setting 6pdrhplug Eop

SERVICE DATA AND SPECIFICATIOI{S

Modelandmal@ BP-sES.
NGK
L46PW;HITACHI
Size(screw
dia.x reach) mm(in) ......................... la x 19(0.551x 0.748)
....................
Pluggap mm(in) ..........,,.,,....,..... 0.8to 0.9(0.031ro 0.035)
.............,,.,..,
Tightening
torque kg-m(ft-lb) ...............-... ....................
1.51o2.0(l1to14)

TROUBLEDIAGNOSESA1{DCORRECTTOI{S
l. Whenenginedoesnot start, high t€nsion cable from spalk plug, After checkinSthis, repair as neces'
Ifthere is no houblein fuel system, startingengineand obsefvingcondi. sary.
ignition system should be checked. tion of sparkthat oc.ursbetween
high
This canb€ easilydoneby d€laching a tensioncableand sparkplugterminal.

SparkIength Troublelocation Probablecause Corrective

action

No sparksat all Distrbutor Defectiveinsulationof condenser. Replace,

oflead.wireon low tensionside,
Breakage Repair.
insulationofcap androtorhead.
Defective Replace.
Pointdoesnot openor close, Repair.
Ignitioncoil Wirebreakage
or shorlcircuitof coil. Replace
with a n€wone.
HEh tensioncable Wirecomingoff. Repair.
D€fcctiveinsulation. Replac€.

I to 2 nm (0.0394 Distributor Pointgaptoo wide. Correct.

to 0.0?87in) or Oil stickingon point. Clean.
irregular.
Pointburnt too much. Replace.

Lessthan 6 mln Sparkplugs Electiodegaptoo wide.

(0.2362in) Cleanor replace.
Brokenneckof insulator. Replace.
Expirationof pluglife. Replace.

'2.
f,rhcn enginetums over but does
not run sxnootl y.
In this cas€,there are many caus€s
EngineElectricalSystem
rcsulting from tlre ignition systemand spection of ignition syst€mshould be
other engin€conditions not related tb
igntion. Therefore, first complete in-

Trouble Troublelocation Probablecause Corrective

action
Enginemisses. Distributor Dirty point. Clean.
Improperpointgap. Correct.
IJak of €lectricityof capandrotor.head. Repairorraplace.
Defectiveinsulationof condens€r. Replace.
Defectivearm. Oil straft.
Defective
springolaIm. R€plaaeassembly.
Breokrge
ofleadwire. R€place.
Womout or shakybreakerplate. Replaceassembly.
Wornout or shakydistributorshaft. Replaceassembly.
lgnitloncoil L,ayer$ort circuitor useofinferior quality. Replace
with goodone.
Hight€nsioncode Deterlorationof insulation and leak of Replace.
elechicity.
Sparkplu8s Dirty. Clean.
L€ak ol electricityat upper porcelainlnsu- Repairor replace.
lator.

Engineknocks Distribuior Improperandadvance timlng, Correctthe fi ing,

veryoften.
Coming off or breakageof governor
sprjng. Cprr€ctor replace.
A pin or a holeof govefiorportionworn Replace.

Sparkplugr Burnttoo much, R€place.

Bnginedoesnot Distributor Improperandretarded timing. Correci tlle fitting.

give€ndugh
power. Defective
functionof Sovemor, Replace
assembly.
Drti point. Clean.
Pointgaptoonarrow. Correct.
Sparkplugs Drty, Clean.