Starting System & Charging System (2.5L): Generator: Disassembly

Remove the four through-bolts.

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

Fig 2: Heating Rear Cover Of Generator Using Drier
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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: Inserting End Of Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
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Using a vise, support the rotor and remove the pulley nut, and remove the rotor from the front cover.
CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Fig 4: Removing Rotor From Front Cover
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Fig 5: Generator Components Location
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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: Locating Bearing Retainer Bolts
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2. Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.
  
  Fig 7: Attaching Tool To 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: Removing Bearings From Rotor Using Bearing Puller
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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: Disconnecting Connection Between 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: Locating IC Regulator Screws
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2. Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
  
  Fig 11: Removing IC Regulator
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Use the following procedures to remove the brush.
1. Remove the cover A.
  
  Fig 12: Locating Cover A Of Generator
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2. Remove the cover B.
  
  Fig 13: Locating Cover B Of Generator
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3. Disconnect the connection and remove the brush.
  
  Fig 14: Removing Brush Of Starter
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4. Remove the rectifier as follows.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Locating Rectifier Bolts
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2. Remove the cover on terminal B.
  
  Fig 16: Locating Cover Of Terminal B
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3. Remove the nuts of terminal B, then remove the rectifier.
Fig 17: Locating Nuts Of Terminal B
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