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Alternator Overhaul: Overhaul

NOTE: Refer to the EXPLODED VIEW  as needed during this procedure.
  1. Test the alternator and regulator before you remove them (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ).
  2. Remove the alternator (see REMOVAL ).

    3. Alternator Disassembly 

  3. 2012 model: If the front bearing needs replacing, remove the over-run alternator decoupler (OAD) pulley (see OVER-RUN ALTERNATOR DECOUPLER (OAD) PULLEY REMOVAL AND INSTALLATION - '12 MODEL ).
  4. 2009 - 2011 models: 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.
    5. Fig 1: Removing Pulley Lock Nut
    G05963898Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the three flange nuts.
    Fig 2: Identifying Flange Nuts
    G05963899Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Remove the end cover (A) and the terminal insulator (B).
    Fig 3: Identifying Cover And Terminal Insulator
    G05963900Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Remove the brush holder assembly (A).
    Fig 4: Identifying Brush Holder Assembly
    G05963901Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Remove the four bolts, then remove the rear housing assembly (A) and the washer (B).
    Fig 5: Identifying Rear Housing Assembly And Washer
    G05963902Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. If you are not replacing the front bearing, go to step  14Remove the rotor from the drive end housing.
    Fig 6: Identifying Rotor From Drive End Housing
    G05963903Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. 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 11.

    Front Bearing Replacement 

  11. Remove the front bearing retainer.
    Fig 7: Identifying Front Bearing Retainer
    G05963904Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Drive out the front bearing with a brass drift and hammer.
    Fig 8: Tapping Front Bearing
    G05963905Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install a new front bearing (A) in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the attachment, 42 x 47 mm.
    Fig 9: Tapping Front Bearing In Drive Housing
    G05963906Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Alternator Brush Inspection 

  14. 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 15.

    Alternator Brush Length 

    Standard (New): 10.5 mm (0.413 in.) 

    Service Limit: 1.5 mm (0.059 in.) 

    Fig 10: Measuring Length Of Both Brushes
    G05963907Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Rotor Slip Ring Test 

  15. Check for continuity between the slip rings (A).
    • If there is continuity, Go to step 16.
    • If there is no continuity, replace the rotor assembly.
    Fig 11: Identifying Slip Ring And Rotor With Rotor Shaft
    G05963908Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
    • If there is no continuity, go to step 17.
    • If there is continuity, replace the rotor assembly.

    Alternator Reassembly 

  17. 2009 - 2011 models: If you removed the pulley, put the rotor in the drive end housing, then tighten its locknut to 110 N.m (11.2 kgf.m, 81 lbf.ft).
  18. 2012 model: If you removed the OAD pulley, install the over-run alternator decoupler (OAD) pulley (see OVER-RUN ALTERNATOR DECOUPLER (OAD) PULLEY REMOVAL AND INSTALLATION - '12 MODEL ).
  19. Remove any grease or any oil from the slip rings.
  20. Put the rear housing assembly and the drive end housing/rotor assembly together, tighten the four through bolts.
  21. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (0.063 in) diameter) to hold them there.
    Fig 12: Pushing Brushes
    G05963909Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Install the brush holder, and pull out the pin or drill bit.
    Fig 13: Pulling Out Pin
    G05963910Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Install the end cover.
  24. After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise.
  25. Install the alternator (see INSTALLATION ).
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