Alternator Overhaul: Disassembly

NOTE:  Refer to the Exploded View if needed during this procedure.

1. Terminal Insulator and Bracket - Remove

   Courtesy of HONDA, U.S.A., INC.

2. Cover - Remove

   Courtesy of HONDA, U.S.A., INC.

3. Brush Holder/Regulator - Remove

   Courtesy of HONDA, U.S.A., INC.

   1. Remove the brush Holder (A), then remove the regulator (B).

4. Stator Assembly - Separate

   Courtesy of HONDA, U.S.A., INC.

   1. Remove the four through bolts.

   Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC. Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC. Properly installed:  Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC. Improperly installed:  Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.

   2. Separate the front housing (A) from the stator core (B) by inserting a flat-tip screwdriver into the openings and prying them apart. NOTE:  Be careful not to damage the stator coil with the tip of the screwdriver. Do not remove the bearing holder (C) from the stator assembly (D). If the bearing holder is not installed properly, replace the stator as assembly.

5. Brush - Inspect

   Courtesy of HONDA, U.S.A., INC.

   1. Measure the length of both brushes with a vernier caliper. If either brush is shorter than the service limit, replace the brushes.

   Alternator Brush Length
   Standard (New):	14 mm (0.55 in)
   Service Limit:	4.5 mm (0.177 in)

6. Pulley - Remove

   Courtesy of HONDA, U.S.A., INC.

   1. Clamp the rotor in a soft-jawed vise. 2. With OAD: Remove the OAD Pulley . 3. Without OAD: Remove the pulley nut, then remove the pulley.

7. Rotor Slip Ring - Test

   Courtesy of HONDA, U.S.A., INC.

   1. Check for continuity between the slip rings (A): If there is continuity, go to step 2. If there is no continuity, replace the rotor assembly. 2. 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. If there is continuity, replace the rotor assembly.

8. Spacer Ring/Front Bearing Retainer - Remove

   Courtesy of HONDA, U.S.A., INC.

9. Front Bearing - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Drive out the front bearing with a brass drift and a hammer.