Alternator Overhaul

Exploded View 

Fig 1: Identifying Alternator Replacement Components With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver Handle, 15 x 135L 07749-0010000
• Bearing Driver Attachment, 42 x 47 mm 07746-0010300

Alternator Disassembly 

1. Test the alternator and regulator (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING  ) before you remove them.
2. Remove the alternator (see DRIVE BELT AUTO-TENSIONER AIR BLEEDING  ).
3. 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 2: Identifying Alternator Nut

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Remove the three flange nuts.
   Fig 3: Identifying Flange Nuts

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5. Remove the end cover (A) and the terminal insulator (B).
   Fig 4: Identifying Terminal Insulator & Cover

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6. Remove the brush holder assembly (A).
   Fig 5: Identifying Brush Holder Assembly

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7. Remove the four bolts, then remove the rear housing assembly (A) and the washer (B).
   Fig 6: Identifying Housing Assembly & Washer

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8. If you are not replacing the front bearing, go to step  13. Remove the rotor from the drive-end housing.
   Fig 7: Identifying Drive-End Housing With Rotor

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9. 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.
10. Remove the front bearing retainer.
    Fig 8: Identifying Front Bearing Retainer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Drive out the front bearing with a brass drift and a hammer.
    Fig 9: Tapping Front Bearing With Brass Drift & Hammer

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12. Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15x135L, and the attachment, 42 x 47 mm.
    Fig 10: Tapping Front Bearing In Housing With Hammer & Driver

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Alternator Brush Inspection 

13. Measure the length of both brushes (A) with a 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 11: Measuring Length Of Both Brushes

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    Rotor Slip Ring Test 

14. 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 12: Identifying Slip Rings & Rotor With Rotor Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. 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.

    Alternator Reassembly 

16. If you removed the pulley, put the rotor in the drive-end housing, then tighten its lock nut to 110 N.m (11.2 kgf.m, 81.0 lbf.ft).
17. Remove any grease or any oil from the slip rings.
18. Put the rear housing assembly and the drive-end housing/rotor assembly together, tighten the four through bolts.
19. 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 13: Pushing Brushes

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20. Install the brush holder assembly, and pull out the pin or drill bit.
    Fig 14: Pulling Out Pin

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Install the end cover.
22. After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise.
23. Install the alternator (see INSTALLATION  ).