Disassembly and Assembly

DISASSEMBLY




1. Heat the portion (A) of rear cover to 50 °C (122 °F) with heater drier.




2. 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.




3. Hold the rotor with a vise and remove the pulley nut.






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




4. Unsolder connection between rectifier and stator coil to remove the stator coil.

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




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




6. Remove the brushes by unsoldering at the pig-tails.




7. Remove the nut and insulating bushing at terminal B, and remove the rectifier.

ASSEMBLY
To assemble, reverse the 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) diameter, 4 - 5 cm (1.6 - 2.0 in.) long wire (A) through the hole shown in the figure.






CAUTION: Be sure to remove the wire after reassembly.

2. Heat the bearing box in the rear bracket [50 - 60 °C (122 - 140 °F)] and press the rear bearing into the rear bracket.

CAUTION: Grease should not be applied for the rear bearing. Remove oil completely if it is found on the bearing box.

3. After reassembly, turn the pulley by hand to check that the rotor turns smoothly.