Generators & Regulators: Overhaul: Generator: Disassembly

Remove the 4 through-bolts shown in Fig 1 .
Heat the portion (A) of rear cover to 122°F (50°C) with heater drier. See Fig 2 .
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.
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).
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.
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.
Unsolder connection between rectifier and stator coil to remove stator coil. See Fig 9 .
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 .
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 .
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.