Disassembly and Assembly

Generator

DISASSEMBLY




1. Remove the four through bolts. Then insert the tip of a flat-head screwdriver into the gap between the stator core and front bracket. Pry then apart to disassemble.




2. Hold rotor with a vise and remove pulley nut.






CAUTION: When holding rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of the vise to prevent rotor from damage.




3. Unsolder connection between rectifier and stator coil to remove stator coil.

CAUTION: Finish the work rapidly (less than three seconds) because the rectifier cannot withstand heat very well.




4. Remove screws which secure IC regulator to rear cover and unsolder connection between IC regulator and rectifier to remove IC regulator.




5. Remove the brushes by unsoldering at the pigtails.




6. Remove the nut and insulating bushing at terminal B. Remove rectifier.

ASSEMBLY




To assemble, reverse order of disassembly.
1. Pulling up brush
Before assembling, press the brush down into the brush holder with your finger and secure in that position by passing a [2 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire through the hole shown in the figure.

CAUTION: Be sure to remove the wire after reassembly

2. Heat the rear bracket [50 to 60 °C (122 to 140 °F)] and press the rear bearing into the rear bracket. Then lubricate the rear bracket.
3. After reassembly, turn the pulley by hand to check that the rotor turns smoothly.