Reassembly
INSTALL OR CONNECTInstalling Brushes To Regulator:
1. Brushes to regulator.
A. Install brush springs and brushes to regulator so that the label on each brush is 2 to 3 mm (0.008 inch to 0.012 inch) from the rectifier.
B. Solder brush lead wires to regulator terminals.
C. Install brush lead wire cover.
2. Brush holder to regulator.
3. Regulator and brush holder to rear housing.
4. Remove hole plug from rear housing.
Supporting Brushes With Wire:
5. Support brushes with a wire inserted through the hole in the rear housing.
6. Rectifier to rear housing; secure with one nut.
Tighten
^ Generator rectifier nut to 33 N.m (24 lb. ft.).
7. Stator to rear housing; secure with four retaining screws.
8. Solder stator leads to rectifier.
9. Battery terminal retaining nut to rear housing.
Tighten
^ Battery terminal retaining nut to 10 N.m (89 lb. in.).
10. Rear bearing to rotor.
11. Front bearing and front bearing retainer to front housing; secure with four screws.
12. Rotor with spacer to front housing.
13. Place the front housing and rotor into a vise, facing the drive pulley end up.
NOTE: To prevent damage to the rotor, place clean shop cloths between the rotor and vise.
14. Drive pulley and drive pulley washer to rotor; secure with retaining nut.
Tighten
^ Drive pulley retaining nut to 65 N.m (48 lb. ft.).
15. Remove the front housing and rotor from the vise.
16. Using a heat gun, heat the rear housing to approximately 50 to 60°C (122 to 140°F).
17. Front housing (with drive pulley and rotor) to stator coil and rear housing, aligning generator housing matchmarks; secure with four generator housing bolts.
Tighten
^ Generator housing bolts to 17 N.m (10 lb. ft.).
18. Remove the brush support wire and install the hole plug into the rear housing.
Inspect
^ Make sure that the rotor rotates smoothly by turning the drive pulley.