Overhaul

GENERATOR ASSEMBLY

DISASSEMBLY AND ASSEMBLY





Required Special Tool:
^ MB992226: Serration Socket

DISASSEMBLY SERVICE POINTS

[A] PULLEY REMOVAL





1. Set the special tool MB992226 to the pulley.





2. Set the closed wrench to the hexagonal area of the special tool MB992226.





3. Insert the hexagonal bit socket having width across flats of 10 mm into the hexagonal area of the rotor shaft.
4. Hold the pulley with the closed wrench. Rotate the rotor shaft clockwise to remove the pulley.

[B] FRONT BRACKET REMOVAL

CAUTION

Do not insert the screwdriver blades too deep. Doing so could damage the stator coil.

Insert the blades of screwdrivers between the front bracket and stator core, and pry and separate them with the screwdrivers.

[C] STATOR / REGULATOR ASSEMBLY

REMOVAL





1. Remove 6 installation screws of the stator lead wire, and then remove the stator.
2. Remove 4 installation screws of the regulator to remove the regulator assembly.

INSPECTION

PULLEY





1. Set the special tool MB992226 to the pulley.
2. Fix the special tool MB992226, with the glasses wrench to prevent the rotor shaft from rotating.
3. Lock the pulley when rotating it clockwise. Check that the pulley rotates smoothly when rotating it counterclockwise.

CAUTION
Locking the one-way clutch might cause the damaged drive belt and an abnormal noise.

ROTOR





1. Measure the resistance between the two slip rings of the rotor coil to check the continuity between them.
Replace the rotor if the resistance is not within the standard value range.

Standard value: 2.0 - 2.3

2. Check the continuity between the slip rings and core.





3. If continuity is present, replace the rotor.

STATOR





1. Check the continuity between coil leads. If there is no continuity, replace the stator.





2. Check the continuity between coil and core. If there is continuity, replace the stator.

RECTIFIER ASSEMBLY





Use the analog type tester to make sure the electrical continuity of each diode meets the table.
Unless the electrical continuity of each diode meets the table, replace the rectifier.





BRUSH





1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit.

Limit: 2 mm (0.1 inch) minimum

2. Unsolder the lead of the brush. The brush will come out, becoming ready for removal.





3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.

REASSEMBLY SERVICE POINTS

]A[ REGULATOR ASSEMBLY INSTALLATION





After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.

NOTE:
Unless inserting the wire to fix the brush, the rotor installation is difficult.

]B[ ROTOR INSTALLATION





Remove the brush holding wire after the rotor has been installed.

]C[ PULLEY INSTALLATION
1. Clean the inner race of the front bearing and that of the pulley.





2. Screws the inner race of the pulley until it touches the inner race of the front bearing.





3. Set the special tool MB992226 to the pulley.





4. Set the closed wrench to the hexagonal area of the special tool MB992226.





5. Insert the hexagonal bit socket having width across flats of 10 mm (0.4 inch) into the hexagonal area of the rotor shaft.
6. Hold the pulley with the closed wrench.
Rotate the hexagonal bit socket counterclockwise to tighten it to the specified torque.

Specified torque: 73 ± 12 Nm (54 ± 8 ft-lb)