Disassembly and Reassembly

1. Front bracket assembly
2. Generator pulley
3. Rotor assembly
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 Steps
To disassemble follow the steps listed above and note the following:




Step 1: Front Bracket Assembly Removal
Insert a flat-tipped screwdriver into the gap between the front bracket assembly and the stator core, and twist the screwdriver to separate the stator and the front bracket assembly.


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

Generator Pulley Removal:

Step 2: Pulley Removal
Secure the rotor in a vise with the pulley side facing upward, and then remove the pulley.


CAUTION: Be careful not to damage the rotor.

Stator/Regulator And Brush Holder Removal:

Step 8/10: Stator/Regulator Assembly Removal
1. Use a soldering iron (180 to 250 W) to unsolder the stator. This work should complete within approximately four seconds to prevent heat from transferring to the diode.
2. Separate the soldered points of the rectifier when removing the rectifier from the regulator assembly.


CAUTION:
1. Be careful not to let the heat from the soldering iron be transmitted to the diodes for a long period of time.
2. Use care that no undue force is exerted to leads of diodes.


Reassembly Steps
To reassemble reverse the steps listed above and note the following :




Step 10: Regulator Assembly Installation
After installing the regulator assembly, insert a wire into the hole in the rear bracket while inserting the brush to secure the brush.


NOTE: Inserting wire in this way will secure the brush and make it easier to install the rotor.

Rotor Assembly Installation:

Step 3: Rotor Assembly Installation
After installing the rotor, remove the wire which was inserted in order to secure the brush.