Alternator Overhaul: Reassembly

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

1. Front Bearing - Install

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

   1. Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the attachment, 42 x 47 mm.

2. Spacer Ring/Front Bearing Retainer - Install

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

3. Pulley - Install

   1. Install the front housing and the rotor. 2. With OAD: Install the OAD pulley . 3. Without OAD: Clamp the rotor in a soft-jawed vise, then tighten the pulley lock nut.

   Fig 1: Pulley Lock Nut With Torque Specifications

   Courtesy of HONDA, U.S.A., INC.
4. Stator Assembly - Install

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

   1. Install the front housing (A) and the stator assembly (B). NOTE:  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.

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

   2. Install the four through bolts.

5. Brush Holder/Regulator - Install

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

   1. Install the regulator (A), then install the brush Holder (B).

6. Cover - Install

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

7. Terminal Insulator and Bracket - Install

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