Alternator Overhaul: Overhaul

NOTE: Refer to EXPLODED VIEW as needed during this procedure.

Test the alternator and regulator before you remove them (see CHARGING SYSTEM INDICATOR CIRCUIT TROUBLESHOOTING ).
Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.

Fig 1: Removing Pulley Locknut With 10 MM & 22 MM Wrenches
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the three flange nuts.

Fig 2: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the end cover (A) and the insulator (B).

Fig 3: Removing End Cover & Insulator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder.

Fig 4: Removing Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the four bolts, then remove the rear housing assembly (A) and washer (B).

Fig 5: Removing Rear Housing Assembly & Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are not replacing the front bearing, go to step 13. Remove the rotor from the drive end housing.

Fig 6: Removing Rotor From Drive End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive end housing for seizure marks.
- If the rotor is damaged, replace the rotor assembly.
- If the rotor is OK, go to step 10.
Remove the front bearing retainer plate.

Fig 7: Removing Front Bearing Retainer Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive out the front bearing with a brass drift and hammer.

Fig 8: Driving Out Front Bearing With Brass Drift & Hammer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
With a hammer and special tools, install a new front bearing in the drive end housing.

Fig 9: Installing New Front Bearing In Drive End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Alternator Brush Inspection
Measure the length of both brushes (A) with vernier caliper (B).
- If either brush is shorter than the service limit, replace the brush holder assembly.
- If the brush length is OK, go to step 14.
  Alternator Brush Length
  - Standard (New): 10.5 mm (0.41 in.)
  - Service Limit: 1.5 mm (0.06 in.)
  Fig 10: Measuring Length Of Both Brushes With Vernier Caliper
  Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rotor Slip Ring Test

Check for continuity between the slip rings (A).
- If there is continuity, go to step 15.
- If there is no continuity, replace the rotor assembly.
  
  Fig 11: Checking For Continuity Between Rotor Slip Rings
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
- If there is no continuity, replace the rear housing assembly, and go to step 16.
- If there is continuity, replace the rotor assembly.

Alternantor Reassembly

If you removed the pulley, put the rotor in the drive end housing, then torque it's locknut to 110N.m (11.2 kgf.m, 81.0 lbf.ft)
Remove any grease or any oil from the slip rings.
Put the rear housing assembly and drive end housing/rotor assembly together, torque the four through bolts.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (0.06 in.) diameter) to hold them there.

Fig 12: Pushing Brushes In & Inserting Pin Or Drill Bit To Hold Them There

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Install the brush holder, and pull out the pin.

Fig 13: Installing brush holder and pulling out the pin

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Install the end cover.
After assembling the alternator, turn the pulley by hand to make sure the rotor smoothly and without noise.
Install the alternator (see Installation ) and drive belt (see Drive Belt Replacement ).