Generators & Regulators: Overhaul: Generator: Disassembly

1. Remove the 4 through-bolts shown in Fig 1 .
2. Heat the portion (A) of rear cover to 122°F (50°C) with heater drier. See Fig 2 .
3. Insert the tip of a flat-head screwdriver into the gap between the stator core and front cover. Pry them apart to disassemble. See Fig 3 .
   CAUTION: To prevent rotor damage when holding rotor with vise, insert aluminum plates or wood pieces on vise's contact surfaces.
4. Hold rotor with a vise and remove pulley nut. See Fig 4 and Fig 5 .
   CAUTION: Rectifier cannot withstand heat well. Finish below steps rapidly (less than three seconds).
5. Remove the ball bearing as follows:
   1. Remove bolt, then remove bearing retainer. See Fig 6
   2. Firmly install to bearing inner race an appropriate tool, such as a fit socket wrench. See Fig 7 .
   3. Push the ball bearing off the front cover using a press.
6. Remove bearing from rotor using a bearing puller. See Fig 8 .
   CAUTION: The rectifier cannot withstand heat well. Do not allow the 180-270 watt soldering bit to contact the terminals for more than 5 seconds at a time.
7. Unsolder connection between rectifier and stator coil to remove stator coil. See Fig 9 .
8. Remove IC regulator as follows:
   1. Remove screws that secure the IC regulator to the rear cover. See Fig 10 .
   2. Unsolder connection between IC regulator and rectifier to remove IC regulator. See Fig 11 .
9. Remove brush as follows:
   1. Remove cover A. See Fig 12 .
   2. Remove cover B. See Fig 13 .
   3. Separate brush from connection to remove. See Fig 14 .
10. Remove rectifier as follows:
    1. Remove bolts that secure rectifier. See Fig 15 .
    2. Remove terminal B's cover. See Fig 16 .
    3. Remove nut from terminal B. See Fig 17 . Remove rectifier.

Fig 1: Removing Front Cover Through-Bolts

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Fig 2: Heating Generator Rear Cover

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Fig 3: Prying Apart Stator Core & Front Cover

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Fig 4: Removing Pulley Nut

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Fig 5: Identifying Rotor & Front Cover Components

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Fig 6: Removing Generator Bolt & Bearing Retainer

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Fig 7: Removing Front Bearing

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Fig 8: Removing Bearing From Rotor Using Bearing Puller

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Fig 9: Unsoldering Rectifier & Stator Connection

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Fig 10: Removing IC Regulator Screws

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Fig 11: Removing IC Regulator

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Fig 12: Removing Generator Brush (1 Of 3)

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Fig 13: Removing Generator Brush (2 Of 3)

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Fig 14: Removing Generator Brush (3 Of 3)

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Fig 15: Removing Generator Rectifier (1 Of 3)

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Fig 16: Removing Generator Rectifier (2 Of 3)

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Fig 17: Removing Generator Rectifier (3 Of 3)

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