2.5 L Model

Remove the four through bolts.

Fig 1: Locating Four Through Bolts
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Use a drier to heat the rear cover (A) portion to 50°C (122°F).

Fig 2: Identifying Rear Cover
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Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Identifying Screwdriver Inserted Into Gap Between Stator Core And Front Cover
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Using a vise, support the rotor and remove the pulley bolt.

Fig 4: Identifying Rotor And Pulley Bolt
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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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Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 6: Identifying Bearing Retainer
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2. Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
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3. Use the press to push the ball bearings out from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Identifying Bearings With Rotor
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Disconnect the connection between the rectifier and stator coil, then remove the stator coil.
CAUTION: The rectifier is easily damaged by heat. Do not allow a 180 - 270 W soldering iron to contact the terminals for 5 seconds or more at a time.

Fig 9: Identifying Rectifier And Stator Coil
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Use the following procedures to remove the IC regulator.
1. Remove the screws which secure the IC regulator to the rear cover.
  
  Fig 10: Identifying IC Regulator Mounting Screws
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2. Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
Fig 11: Disconnecting Connection Between IC Regulator And Rectifier
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Use the following procedures to remove the brush.

Remove the cover A.

Fig 12: Identifying Brush Cover (First)
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Remove the cover B.

Fig 13: Identifying Brush Cover (Second)
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Disconnect the connection and remove the brush.

Fig 14: Identifying Brush
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Remove the rectifier as follows.

Remove the bolts which secure the rectifier.

Fig 15: Locating Rectifier Mounting Bolt
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Remove the cover on terminal B.

Fig 16: Locating Terminal Cover
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Remove the nuts of terminal B, then remove the rectifier.

Fig 17: Locating Terminal Mounting Nut

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