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Chapter 2 Starting and Charging System

Section 1 Starting System

(MR479Q MR479QA MR481QA)

I. STARTER INSPECTION

NOTICE:

These tests must be done within 5 seconds to avoid burning out the coil.

1. INSPECT MAGNETIC SWITCH

(a) Use wire to connect the starter as shown.

(b) Connect the magnetic switch and the battery as

shown.

(c) Disconnect the magnet exciting coil from the

terminal A.

(d) Check if the clutch pinion gear is moving out.

If the clutch pinion gear is not moving out, replace

the magnetic switch.

(e) Connect the battery as shown above. Disconnect

the battery positive (+) from the terminal, to make the clutch pinion gear disengaged.

(f) Check if the clutch pinion gear has returned.

If the clutch pinion gear has not returned, replace

the magnetic switch.

Terminal A

Battery

Battery

Disconnect

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2. INSPECT STARTER NO-LOAD

(a) Connect the magnet exciting coil and the terminal.

(b) Connect the ammeter and the battery to the starter

as shown.

(c) Check that the starter rotates smoothly and steadily

with the clutch pinion gear moving out.

(d) Check that the ammeter shows the specified

current.

Specified current: 90 A or less at 11.5 V

if the current is not normal, replace the starter.

3. WIRING

(a) Check that the connecting wire between

the positive (+) and the starter is stable

and reliable, and the insulating bush is in

good condition, in order to avoid a fire

caused by electric spark.

(b) Check that there is continuity in the wire

and if the insulating bush is not damaged.

If the harness is damaged, replace it.

Ammeter

Ignition Switch

Battery

Main Fuse Box

Starter

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II. STARTER ASSEMBLY REPLACEMENT (MR479Q, MR479QA, MR481QA)

1. REMOVE STARTER ASSEMBLY

(a) Disconnect the starter connector.

(b) Remove the nut, and disconnect the starter

cable.

(c) Remove the 2 bolts and the starter

assembly.

2. INSTALL STARTER ASSEMBLY

Install according to the inverted order of removal.

Torque:

Bolt 37N.m (378kgf.cm, 27ft.lbf)

Harness 9.8N.m(100kgf.cm, 7.0ft.lbf)

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Section 2 Charging System

(MR479Q, MR479QA, MR481QA)

I. BATTERY

Maintenance-free battery is applied in this vehicle. Its termination voltage is 12V. It is connected inline by six

2V single cell in tandem with walls between every pole.

1. BATTERY WARNING SIGNS

1 -- Danger of corrosion

The battery electrolyte is very corrosive. DO NOT overturn the battery.

2 -- Read the instructions for battery

3 -- Children are forbidden to touch the battery

4 -- Avoid fire, electromagnetic wave and strong light.

 Avoid electric spark while repair; avoid short.

5 -- Wear protecting glasses

6 -- Danger of explosion

The explosive mixed gas will be produced while charging.

7 -- How to deal with a scrapped battery

The scrapped battery should be delivered to the collection station.

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