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Generators & Regulators: Overhaul

NOTE: Use exploded view of generator for overhaul. See Fig 1.
Fig 1: Exploded View Of Alternator
G00303589Courtesy of AMERICAN HONDA MOTOR CO., INC.
  1. Test the alternator and regulator before you remove them. See CHARGING SYSTEM INDICATOR TEST  under TROUBLE SHOOTING.
  2. Remove the alternator. See ALTERNATOR  under REMOVAL & INSTALLATION.
  3. 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. See Fig 2.
  4. Remove the 3 flange nuts and the terminal insulator from the alternator. See Fig 3.
  5. Remove the end cover "A" and seal ring "B". See Fig 4.
  6. Remove the brush holder assembly "A" and seal ring "B". See Fig 5.
  7. Remove 4 bolts. Remove the rear housing assembly "A", washer "B", and rear bearing cover "C". See Fig 6.
  8. If you are not replacing the front bearing and/or rear bearing, go to BRUSHES . Remove the rotor from the rotor drive-end housing. See Fig 7.
  9. 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 next step.
  10. Remove the rear bearing using a puller. See Fig 8.
  11. With a hammer, driver and attachment, install a new rear bearing in the rotor shaft. See Fig 9.
  12. Remove the front bearing retainer plate. See Fig 10.
  13. Drive out the front bearing with a brass drift and hammer. See Fig 11.
  14. With a hammer, driver and attachment, Install a new front bearing in the drive end housing. See Fig 12.
Fig 2: Removing Pulley Locknut
G00215497Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 3: Removing Three Flange Nuts
G00215501Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 4: Removing End Cover And Seal Ring
G00215489Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 5: Removing Brush Holder And Seal Ring
G00215493Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 6: Removing Rear Housing Assembly
G00215505Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 7: Replacing Front/Rear Bearings
G00215509Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 8: Removing Rear Bearing
G00215513Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 9: Installing New Rear Bearing
G00220684Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 10: Removing Front Bearing Retainer Plate
G00220688Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 11: Driving Out Front Bearing
G00220692Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 12: Installing New Front Bearing
G00220696Courtesy of AMERICAN HONDA MOTOR CO., INC.
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