Charging System: Service and Repair

Construction






Disassembly and Assembly






1. Remove rear cover.
^ Heat rear cover, using heat gun, to 50° C (90° F) above room temperature to prevent bearing damage.






2. Disconnect stator/diode.
^ Cut diode terminals.
^ Unsolder stator coil leads.

CAUTION: Unsolder stator coil leads as fast as possible to avoid damaging diodes.

3. Remove stator and rotor.
4. Remove bearing retainer and bearing.
5. Assemble in reverse of disassembly.






^ Insert stator coil lead into lower portion of diode terminal.
^ Using pliers, crimp diode terminal around stator coil lead.
^ Be sure stator coil leads do not protrude more than 3 mm (0.118 in.) past diode terminal.






^ Solder stator coil lead and diode terminals.

CAUTION: Solder stator coil leads and diode terminals as fast as possible to avoid damaging diodes. Use 9/1 Pb/Sn solder in assembly.
















REAR COVER INSTALLATION
1. Before installing front cover with pulley and rotor with rear cover, push brush up with fingers and retain brush by inserting brush lift wire into brush lift hole from outside.
2. After installing front and rear sides of generator, pull out brush lift wire.