Alternator Overhaul: Overhaul

NOTE: Refer to the EXPLODED VIEW if needed during this procedure.

Test the alternator and regulator before you remove them (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ).
Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
Alternator Disassembly
If the front bearing needs replacing, remove the over-run alternator decoupler (OAD) pulley (see OVER-RUN ALTERNATOR DECOUPLER (OAD) PULLEY REMOVAL AND INSTALLATION ).
Remove the three flange nuts.

Fig 1: Identifying Front Bearing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the end cover (A) and the terminal insulator (B).

Fig 2: Identifying End Cover And Terminal Insulator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder assembly (A).

Fig 3: Identifying Brush Holder Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the four through bolts, then remove the rear housing assembly (A) and the washer (B).

Fig 4: Identifying Rear Housing Assembly And 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 5: Identifying Rotor Of 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.

Fig 6: Identifying Front Bearing Retainer With Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive out the front bearing with a brass drift and a hammer.

Fig 7: Driving Front Bearing Using Hammer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.

Fig 8: Installing Front Bearing On Drive-End Housing Using Hammer
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Alternator Brush Inspection
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 (0.413 in)

Service Limit: 1.5 mm (0.059 in)

Fig 9: Identifying Length Of Brushes Using 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 10: Identifying Slip Rings, Rotor And Rotor Shaft
  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, go to step 16.
- If there is continuity, replace the rotor assembly.
Alternator Reassembly
If you removed the OAD pulley, install it (see OVER-RUN ALTERNATOR DECOUPLER (OAD) PULLEY REMOVAL AND INSTALLATION ).
Remove any grease or any oil from the slip rings.
Put the rear housing assembly and the drive-end housing/rotor assembly together, tighten the four through bolts.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.

Fig 11: Pushing Brushes To Insert Pin
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the brush holder assembly, and pull out the pin or drill bit.

Fig 12: Removing Pin Or Drill Bit
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 turns smoothly and without noise.
Install the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).