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Brush Installation

  1. Install brush and spring into holder. Allow brush to extend out of holder until wear limit line extends .08-.16"(2-4 mm) beyond end of brush holder. See Fig 7. Solder pigtail onto brush holder.
  2. Insert spring and brush into brush holder. Using a spring scale, pull brush into holder until end of brush protrudes .08" (2.0 mm) from holder. See Fig 1 thru Fig 6 . Note reading on spring scale. Replace spring if tension is not 5.6-15.5 ozs. (160-440 g).
Fig 1: Heating Rear Bearing Housing
G96D06065Courtesy of MAZDA MOTORS CORP.
Fig 2: Removing Rear Bearing
G96H06067Courtesy of MAZDA MOTORS CORP.
Fig 3: Unsoldering Rectifier From Regulator
G96B06069Courtesy of MAZDA MOTORS CORP.
Fig 4: Replacing Brushes
G96F06071Courtesy of MAZDA MOTORS CORP.
Fig 5: Measuring Brush Spring Tension
G96E06075Courtesy of MAZDA MOTORS CORP.
Fig 6: Inserting Wire To Retain Brushes For Reassembly
G96J06073Courtesy of MAZDA MOTORS CORP.
Fig 7: Measuring Installed Depth Of Brush
G90F02332Courtesy of MAZDA MOTORS CORP.
Fig 8: Exploded View Of Generator (2.0L)
G93B82363Courtesy of MAZDA MOTORS CORP.
Fig 9: Exploded View Of Generator (2.5L)
G93C82364Courtesy of MAZDA MOTORS CORP.
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