Disassembly and Reassembly

Generator - Disassembly And Reassembly:

1. Front bracket assembly
2. Generator pulley
3. Rotor assembly
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
8. Stator
9. Plate
10. Regulator assembly
11. Brush
12. Slinger
13. Rectifier
14. Rear bracket

Disassembly Steps
To disassemble follow the steps listed above and note the following :




Step 1: Front Bracket Assembly Removal
Insert a flat tip screwdriver, etc., in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket.

CAUTION: Do not insert screwdriver too deep, as there is danger of damage to stator coil.

Generator Pulley Removal:

Step 2: Pulley Removal
Face the pulley side upward, fix the rotator with a vise and remove the pulley.

CAUTION: Use care so that the rotor is not damaged.

Stator/Regulator And Brush Holder Removal:

Step 8/10: Stator/Regulator Assembly Removal
1. When removing stator, unsolder three stator leads soldered to main diodes on rectifier.
2. When removing the rectifier from the regulator assembly, remove the soldered sections of the rectifier.

CAUTION:
1. Use care to make sure that the heat of the soldering iron is not transmitted to the diodes for a long period.
2. Use care that no undue force is exerted to leads of diodes.





Reassembly Steps
To reassemble reverse the steps listed above and note the following :

Step 10: Regulator Assembly Installation
After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush.

NOTE: The brush is fixed when a wire is inserted, making rotor installation easier.

Rotor Assembly Installation:

Step 3: Rotor Installation
After installing the rotor, remove the wire used to fix the brush.