Overhaul
DISASSEMBLY AND ASSEMBLYDisassembly Steps 1-14:
DISASSEMBLY SERVICE POINTS
<> FRONT BRACKET ASSEMBLY REMOVAL
CAUTION: Do not insert a screwdriver too deep. The stator coil will be damaged.
Insert a flat-tipped screwdriver between the front bracket assembly and the stator core, and pry it downward to separate the stator and front bracket assembly.
<> GENERATOR PULLEY REMOVAL
CAUTION: Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove the pulley.
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CAUTION:
- Check that the heat from the soldering iron is not transmitted to the diode for a long time.
- Use care that no undue force is exerted to leads of diodes.
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. When removing the rectifier from the regulator assembly, unsolder the points soldered on the rectifier.
ASSEMBLY SERVICE POINTS
>>A<< REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire through the hole provided on the rear bracket while pressing down on the brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place, and the installation of the rotor will be easier.
>>B<< ROTOR ASSEMBLY INSTALLATION
After installing the rotor, remove the wire used to secure the brush.
INSPECTION
ROTOR CHECK
1. Check the continuity between the slip rings of the field coil. If the resistance value is not within the standard value, replace the rotor.
Standard value: approximately 2 - 5 Ohms
2. Check the continuity between the slip ring and the core. If there is continuity, replace the rotor.
STATOR CHECK
1. Check the continuity between the coil lead. If there is no continuity, replace the stator.
2. Check the continuity between the coil and the core. If there is continuity, replace the stator.
RECTIFIER CHECK
1. Check the continuity between the positive rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is shorted, so replace the rectifier.
2. Check the continuity between the negative rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is grounded, so replace the rectifier.
BRUSH CHECK
1. Replace the brush if the brush protrusion length shown in the illustration is the minimum limit value.
Minimum limit: 2 mm (0.08 inch)
2. The brush can be removed by unsoldering the brush lead wire.
3. When installing a new brush, push the brush in to the brush holder, and solder the lead wire.