Alternator: Service and Repair

Generator:

DISASSEMBLY
1. Remove the four through bolts.
2. Insert a flat screwdriver between the front bracket and stator core, and pry downward.

CAUTION:
1. Do not insert the screwdriver too deeply, as there is a danger Of damaging the stator coil




2. The rear cover may be hard to remove be cause a ring is used to lock the outer race of the rear bearing. To facilitate removal of rear cover, heat lust the bearing box with a 200-watt soldering iron. Do not use a heat gun as it may damage the diode assembly.




3. Secure the rotor in a vise with the pulley side up.

CAUTION: Be careful that the vise jaws do not damage the rotor.

4. Remove the pulley nut, spring washer, pulley, and spacer.
5. Remove the front bracket and two seals.
6. Remove the rotor from the vise.
7. Remove the brush holder screws, rectifier screws, and nut from the "B" terminal.
8. Remove the stator assembly from the rear bracket.
9. Detach the Slinger from the brush holder.
10. When the stator is to be removed, unsolder the three stator leads to the main diodes on the rectifier.

CAUTION:
1. When soldering or unsoldering, make sure that heat from soldering iron is not transmitted to the diodes for a long period.
2. Do not exert excessive force on the leads of the diodes.




11. When separating the rectifier from the brush holder, unsolder the two plates soldered to the rectifier.