Disassembly and Reassembly

Generator - Disassembly And Reassembly:

Disassembly Steps
1. Front bracket assembly
2. Generator pulley
3. Rotor
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
To Disassemble follow the steps listed in the image and note the following.




Step 1: Front Bracket Removal
Insert a screwdriver or the like in the clearance between the front bracket assembly and stator core and pry it to separate the stator and front bracket assembly.

CAUTION: Do not insert screwdriver too deep, or stator coil will be damaged.

Generator Pulley Removal:

Step 2: Pulley Removal
Hold the rotor in a vice with the pulley side up and remove the pulley.

CAUTION: Use care to prevent damage to the rotor.

Stator Removal:

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

CAUTION:
1. Use care to prevent applying the soldering iron heat to a diode for a long time.
2. Use care that no undue force is exerted to leads of diodes.

Reassembly
To Reassemble follow the steps listed in the image and note the following.




Step 10: Regulator Assembly Installation
After the regulator assembly has been installed, push the brushes in and insert a metal wire in the hole made in the rear bracket to secure the brushes.

NOTE: Insertion of the metal wire will secure the brushes, making it easier to mount the rotor.

Rotor Assembly Installation:

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