Alternator Disassembly

Test the alternator and regulator before you remove them (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ).
Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.

Fig 1: Identifying Pulley Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the three flange nuts.

Fig 2: Identifying Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the end cover (A) and the insulator (B).

Fig 3: Locating End Cover & Insulator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder (A).

Fig 4: Locating Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the four bolts, then remove the rear housing assembly (A) and washer (B).

Fig 5: Locating Bolts, Rear Housing Assembly & Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are not replacing the front bearing, go to step 1. Remove the rotor from the drive-end housing.

Fig 6: Identifying Rotor & Drive-End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.
- If the rotor is damaged, replace the rotor assembly.
- If the rotor is OK, go to step 10.
Remove the front bearing retainer plate.

Fig 7: Identifying Front Bearing Retainer Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive out the front bearing with a brass drift and hammer.

Fig 8: Driving Out Front Bearing With Brass Drift & Hammer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install a new front bearing in the drive-end housing with a hammer, the driver handle, and attachment (42 x 47 mm).

Fig 9: Identifying Front Bearing In Drive-End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.