Starting/Charging Systems (H4SO): Generator: Disassembly

1. Remove the four through-bolts.
   Fig 1: Removing Four Through-Bolts

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2. Heat portion (A) of rear cover to 50° (122°) with a heater drier.
   Fig 2: Heating Portion Of Rear Cover To 50°

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3. 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 A Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover

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4. Hold the rotor with a vise and remove pulley nut.
   Fig 4: Removing Pulley Nut

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   CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.
   Fig 5: Identifying Generator Components

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5. Remove the ball bearing as follows.
   1. Remove the bolt, and then remove the bearing retainer.
      Fig 6: Removing Bolt And Bearing Retainer

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   2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
      Fig 7: Installing Appropriate Tool To Bearing Inner Race

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   3. Push the ball bearing off the front cover using a press.
6. Remove the bearing from rotor using a bearing puller.
   Fig 8: Removing Bearing From Rotor Using A Bearing Puller

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7. Unsolder connection between rectifier and stator coil to remove the stator coil.
   CAUTION: 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: Unsoldering Connection Between Rectifier And Stator Coil

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8. Remove the IC regulator as follows.
   1. Remove the screws which secure IC regulator to rear cover.
      Fig 10: Removing Screws

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   2. Unsolder the connection between IC regulator and rectifier to remove the IC regulator.
   Fig 11: Unsoldering Connection Between IC Regulator And Rectifier

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9. Remove the brush as follows.
   1. Remove cover A.
      Fig 12: Removing Cover A

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   2. Remove cover B.
      Fig 13: Removing Cover B

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   3. Separate the brush from connection to remove.
   Fig 14: Separating Brush From Connection

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10. Remove the rectifier as follows.

1. Remove the bolt which secures the rectifier.
   Fig 15: Removing Bolt From Rectifier

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2. Remove the cover of terminal B.
   Fig 16: Removing Cover Of Terminal B

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

Fig 17: Removing Nut Of Terminal B And Rectifier

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