Generator Disassembly: Notes

NOTE: Insert protective material in the jaws of the vise.

NOTE: If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear housing fit together very tightly.

NOTE: Disconnect quickly. If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat.

Remove four cap screws from rear housing. See Fig 1 .

Fig 1: Removal of Screws from Rear Housing
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Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear housing. See Fig 2 .

Fig 2: Bearing Removal from Rear Housing
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Use a flat-blade screwdriver to separate front housing from stator. See Fig 3 .

Fig 3: Remove Front Housing from Stator
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Place rotor in a vise and loosen locknut, then disassemble pulley, rotor, and front housing. See Fig 4 .

Fig 4: Disassemble Pulley, Rotor, & Front Housing
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Fig 5: Generator Trouble Shooting
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Fig 6: Generator Circuit Diagram
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If necessary, remove front bearing using a socket and a hand press or vise. See Fig 7 .

Fig 7: Removing Front Bearing With A Socket
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Remove rear bearing with a bearing puller. See Fig 8 .

Fig 8: Removing Rear Bearing With A Puller
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Remove "B" terminal nut and insulating bushing.
Remove five screws holding the rectifier and brush holder. See Fig 9 .

Fig 9: Removing 5 Screws From Rectifier
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Separate rear bracket and stator. See Fig 10 .

Fig 10: Separating Rear Bracket & Stator
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Use a soldering iron to remove solder from rectifier and stator leads, and then remove IC regulator. See Fig 11 .

Fig 11: Using Soldering Iron To Remove Solder From Rectifier
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Replace brushes. Remove solder from pigtail, and then remove brush. See Fig 12 .

Fig 12: Removing Solder From Pigtail
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