Alternator: Service and Repair

WARNING
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. DO NOT ALLOW FLAMES, SPARKS OR LIGHTED TOBACCO TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
^ WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.
^ KEEP BATTERIES OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.

NOTE: The Voltage Regulator (VR) is the only internally serviceable component on this generator.







REMOVAL
1. Disconnect battery ground cable.
2. Remove right side cowl vent screen.
3. Raise vehicle and remove right front wheel assembly.
4. Remove right tie-rod.
5. Remove accessory drive belt from generator.
6. Disconnect electrical harness connector and output terminal wiring.
7. Remove nut and position engine control sensor wiring out of the way.
8. Remove one bolt and two stud bolts.
9. Remove generator from vehicle.

INSTALLATION
1. Follow the removal procedure in reverse order.
2. Tighten generator mounting bolt and stud bolts to 20-30 N.m (15-22 Lb-Ft).
3. Tighten engine control sensor wiring mounting nut to 15-20 N.m (11-14 Lb-Ft).
4. Tighten the generator output nut to 9-12 N.m (80-106 Lb-in).