Starting System & Charging System (H4DO): Generator: Disassembly

Remove the cap from the generator.

Fig 1: Locating Generator Cap
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Remove four bolts.

Fig 2: Locating Generator Bolts
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Use a drier to heat the rear cover (A) portion to 50 - 60°C (122 - 140°F).

Fig 3: Heating Rear Cover Portion Using Drier
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Insert a flat tip screwdriver or similar tool wrapped with protective tape into the gap between stator core and the front cover to disassemble.

Fig 4: Inserting Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
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Hold the rotor on a vise and remove the pulley.
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: Removing Pulley
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Remove the rotor from the front cover.

Fig 6: Identifying Rotor, Front Cover And Pulley
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Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 7: Locating 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 8: 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 9: Removing Bearings From Rotor Using Bearing Puller
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Remove six bolts which connect the rectifier and stator coil, then remove the stator coil.

Fig 10: Locating Stator Coil Bolts
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Remove four screws which secure the IC regulator to the rear cover, then remove the IC regulator.

Fig 11: Locating IC Regulator Screws
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Use the following procedures to remove the brush.
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. Disconnect the connection and remove the brush.
  
  Fig 14: Removing Brush
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Remove the rectifier as follows.
1. Remove the cover on terminal B.
  
  Fig 15: Locating Cover Terminal B
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2. Remove the nut on terminal B.
  
  Fig 16: Locating Terminal B Nut
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3. Remove the bolts which secure the rectifier, and remove the rectifier.
  
  Fig 17: Locating Rectifier Bolts
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