Starting/Charging Systems (H6DO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Locating Four Through-Bolts
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Heat the portion (A) of rear cover to 50°C (122°F) with a heater drier.

Fig 2: Applying Heat To Rear Cover
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Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Flat Tip Screwdriver Into Stator Core And Front Cover
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Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut
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CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Fig 5: Identifying Front Cover, Pulley, Nut And Rotor
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Remove the ball bearing as follows.
1. Remove the bolt, and then remove the bearing retainer.
  
  Fig 6: Identifying Bearing Retainer Bolt
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2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
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3. Push the ball bearing off the front cover using a press.
Remove the bearing from rotor using a bearing puller.

Fig 8: Removing Bearing From Rotor Using Bearing Puller
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Separate the connection between rectifier and stator coil to remove stator coil.
CAUTION: Do not allow a 180 - 270 W soldering iron to contact the terminals for more than 5 seconds at once because the rectifier cannot withstand so much heat.

Fig 9: Unsoldering Connection Between Rectifier And Stator Coil
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Remove the IC regulator as follows.
1. Remove the screws which secure IC regulator to rear cover.
  
  Fig 10: Identifying IC Regulator
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2. Unsolder the connection between IC regulator and rectifier to remove IC regulator.
  
  Fig 11: Unsoldering Connection Between IC Regulator And Rectifier
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Remove the brush as follows.
1. Remove the cover A.
  
  Fig 12: Identifying Cover A
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2. Remove the cover B.
  
  Fig 13: Identifying Cover B
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3. Separate the brush from connection to remove.
  
  Fig 14: Removing Brush From Connection
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Remove the rectifier as follows.
1. Remove the bolts which secure rectifier.
  
  Fig 15: Identifying Rectifier Bolt
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2. Remove the cover of terminal B.
  
  Fig 16: Locating Cover Of Terminal B
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3. Remove the nut of terminal B, and then remove the rectifier.
  
  Fig 17: Locating Nut Of Terminal B
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