Mazda Trucks 1972-1986 Repair Guide

Battery, Starting and Charging Systems


See Figure 1

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Fig. Fig. 1: Jumper wires with various connectors are handy for quick electrical testing



The battery is the first link in the chain of mechanisms which work together to provide cranking of the automobile engine. In most modern vehicles, the battery is a lead/acid electrochemical device consisting of six 2v subsections (cells) connected in series so the unit is capable of producing approximately 12v of electrical pressure. Each subsection consists of a series of positive and negative plates held a short distance apart in a solution of sulfuric acid and water.

The two types of plates are of dissimilar metals. This sets-up a chemical reaction, and it is this reaction which produces current flow from the battery when its positive and negative terminals are connected to an electrical accessory such as a lamp or motor. The continued transfer of electrons would eventually convert the sulfuric acid to water, and make the two plates identical in chemical composition. As electrical energy is removed from the battery, its voltage output tends to drop. Thus, measuring battery voltage and battery electrolyte composition are two ways of checking the ability of the unit to supply power. During engine cranking, electrical energy is removed from the battery. However, if the charging circuit is in good condition and the operating conditions are normal, the power removed from the battery will be replaced by the alternator which will force electrons back through the battery, reversing the normal flow, and restoring the battery to its original chemical state.

Starting System

The battery and starting motor are linked by very heavy electrical cables designed to minimize resistance to the flow of current. Generally, the major power supply cable that leaves the battery goes directly to the starter, while other electrical system needs are supplied by a smaller cable. During starter operation, power flows from the battery to the starter and is grounded through the vehicle's frame/body or engine and the battery's negative ground strap.

The starter is a specially designed, direct current electric motor capable of producing a great amount of power for its size. One thing that allows the motor to produce a great deal of power is its tremendous rotating speed. It drives the engine through a tiny pinion gear (attached to the starter's armature), which drives the very large flywheel ring gear at a greatly reduced speed. Another factor allowing it to produce so much power is that only intermittent operation is required of it. Thus, little allowance for air circulation is necessary, and the windings can be built into a very small space.

The starter solenoid is a magnetic device which employs the small current supplied by the start circuit of the ignition switch. This magnetic action moves a plunger which mechanically engages the starter and closes the heavy switch connecting it to the battery. The starting switch circuit usually consists of the starting switch contained within the ignition switch, a neutral safety switch or clutch pedal switch, and the wiring necessary to connect these in series with the starter solenoid or relay.

The pinion, a small gear, is mounted to a one way drive clutch. This clutch is splined to the starter armature shaft. When the ignition switch is moved to the START position, the solenoid plunger slides the pinion toward the flywheel ring gear via a collar and spring. If the teeth on the pinion and flywheel match properly, the pinion will engage the flywheel immediately. If the gear teeth butt one another, the spring will be compressed and will force the gears to mesh as soon as the starter turns far enough to allow them to do so. As the solenoid plunger reaches the end of its travel, it closes the contacts that connect the battery and starter