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 ).
Remove the four through bolts.

Fig 1: Identifying Alternator Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Heat the rear bearing seat with a heat gun until the rear housing reaches (129-140°F, 50-60°C).

Fig 2: Heating Rear Bearing Seat With Heat Gun
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Separate the rear housing from the drive end housing by inserting a flat-tip screwdriver into the openings, and prying them apart.
NOTE: Be careful not to damage the stator with the tip of the screwdriver.

Fig 3: Separating Rear Housing From Drive End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Separate the rear housing (A) and drive end housing (B) with the stator (C) attached to the rear housing.

Fig 4: Identifying Rear Housing & Drive Housing With Stator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are not replacing the front bearing and/or rear bearing, go to step 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut.

Fig 5: Identifying Pulley Locknut With Soft-Jawed Vise
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the rotor.

Fig 6: Identifying Rotor Housing
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Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive end housing for seizure marks.
- If either the rotor or drive end housing is damaged, replace the alternator.
- If both the rotor and the drive end housing are OK, go to step 10.
Remove the rear bearing using the puller as shown below.

Fig 7: Identifying Rear Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.

Fig 8: Applying Pressure Only On Inner Race
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Remove the front bearing retainer plate.

Fig 9: Identifying Front Bearing Retainer Plate
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Support the drive end housing on some wood blocks, and drive out the front bearing with a brass drift and hammer.

Fig 10: Identifying Front Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
With a hammer, the driver handle, and the attachment, install a new front bearing in the drive end housing.

Fig 11: Identifying Front Bearing & Driver End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the stator.

Fig 12: Identifying Stator Ground Bolts
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Remove the terminal insulator (A) and harness 1 bracket (B).

Fig 13: Identifying Terminal Insulator & Harness Bracket
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Remove the voltage regulator/brush holder assembly (A) and the rectifier (B).

Fig 14: Identifying Voltage Regulator/Brush Holder Assembly & Rectifier
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Check for continuity in each direction, between the B terminal (A) and P terminals (B), and between the E terminal (C) and P terminals (B) of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of six diodes (six pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 24 checks.
- If any diode failed, replace the rectifier assembly. (Diodes are not available separately.)
Fig 15: Identifying Rectifier Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.