Alternator: Service and Repair

COMPONENTS




REMOVAL AND INSTALLATION




1. Disconnect the negative terminal from the battery.




2. Loosen the belt tension.




3. Raise the vehicle.
4. Remove the mud guard - RH
5. Disconnect the generator B+ terminal wire and connector.




6. Remove the belt and generator mounting bolt (2EA).
7. Remove the generator assembly.
8. Installation is the reverse order of removal.

DISASSEMBLY
1. Remove the nut from the "B" terminal, and rear cover.




2. When the stator is to be removed, unsolder the four stator leads to the main diodes on the rectifier.

CAUTION:
1. When soldering or unsoldering, use care to make sure that heat of the soldering iron is not transmitted to the diodes for along period.
2. Use care that excessive force is not exerted on the leads of the diodes.

3. Remove the stator assembly from the rear bracket.
4. Remove the brush holder and the rectifier.
5. Remove the four through bolts




6. Insert a flat screwdriver between the front bracket and stator core, and pry downward.

CAUTION:




1. Do not insert the screwdriver too deeply, as there is a danger of damaging the stator coil.
2. The rear cover may be hard to remove because a ring is used to lock the outer race of the rear bearing. To facilitate removal of rear cover, heat lust the bearing box section with a 200-watt soldering iron. Do not use a heat gun, as it may damage the diode assembly.




7. Secure the rotor in a vise with the pulley side up.

CAUTION: Be careful that the vise jaws do not damage the rotor.

8. Remove the pulley nut, then remove the spring washer, then the pulley, and then the spacer.
9. Remove the front bracket and seals.
10. Remove the rotor from the vise.




11. When separating the rectifier from the brush holder, unsolder the two plates soldered to the rectifier.




REASSEMBLY
Perform reassembly in the reverse procedure of disassembly. Pay attention to the following:
Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to lock the brushes. After the rotor has been installed, the wire can be removed.




INSTALLATION
1. Position the generator and insert the support bolt. (Do not attach the nut.)
2. Push the generator forward and determine how many spacers (thickness: 0.198 mm) should be inserted between the front leg of the generator and the front case (space A in the illustration). (There should be enough spacers so that they do not fall out when you let go of them.)
3. Insert the spacers (space A in the illustration), attach the nut, and complete the installation.