Adjustment - Replacement: Generator: Disassembly

Remove the four through-bolts.

Fig 1: Removing Through-Bolts

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Heat portion (A) of rear cover to 50°C (122°F) with a heater drier.

Fig 2: Heating Portion Of Rear Cover

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Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Tip Of Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover

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Screwdriver

Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut

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IMPORTANT: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Fig 5: Exploded View Of Generator

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Front cover
Pulley
Nut
Rotor

Remove the ball bearing as follows.

Remove the bolt, and then remove the bearing retainer.

Fig 6: Removing Bearing Retainer

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Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.

Fig 7: Pressing Out Bearing Inner Race

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Push the ball bearing off the front cover using a press.

Remove the bearing from rotor using a bearing puller.

Fig 8: Removing Bearing From Rotor Using Bearing Puller

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Unsolder connection between rectifier and stator coil to remove the stator coil.

IMPORTANT: Do not allow a 180 - 270 W soldering iron to contact the
terminals for more than 5 seconds at once because the rectifier cannot withstand so much heat.

Fig 9: Removing Stator Coil

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Remove the IC regulator as follows.

Remove the screws which secure IC regulator to rear cover.

Fig 10: Removing Screws Which Secure IC Regulator To Rear Cover

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Unsolder the connection between IC regulator and rectifier to remove the IC regulator.

Fig 11: Removing IC Regulator

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Remove the brush as follows.

Remove cover A.

Fig 12: Removing Cover

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Cover A

Remove cover B.

Fig 13: Removing Cover A

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Cover B

Separate the brush from connection to remove.

Fig 14: Separating Brush From Connection

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Remove the rectifier as follows.

Remove the bolts which secure the rectifier.

Fig 15: Removing Bolts Which Secure Rectifier

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Remove the cover of terminal B.

Fig 16: Removing Cover Off Terminal

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Remove the nut of terminal B, and then remove the rectifier.

Fig 17: Removing Rectifier

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