Starting/Charging Systems (H4SO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Locating Generator Through-Bolts
Use a drier to heat the rear cover (A) portion to 50°C (122°F).

Fig 2: Applying Heat To Portion Of Rear Cover
Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry these apart to disassemble.

Fig 3: Inserting End Of Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
Using a vise, support the rotor and remove the pulley bolt.

Fig 4: Holding Rotor And Removing Pulley Nut

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

Fig 5: Identifying Generator Components
Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 6: Detaching Bearing Retainer
2. Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
3. Use the press to push the ball bearings out from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Pushing Ball Bearing Off Front Cover
Disconnect the connection between the rectifier and stator coil, then remove the stator coil.
CAUTION: The recitifer is easily damaged by heat. Do not allow a 180 - 270 W soldering iron to contact the terminals for more than 5 seconds at a time.

Fig 9: Unsoldering Connection Between Rectifier And Stator Coil
Use the following procedures to remove the IC regulator.
1. Remove the screws which secure the IC regulator to the rear cover.
  
  Fig 10: Identifying IC Regulator
2. Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
  
  Fig 11: Unsoldering Connection Between IC Regulator And Rectifier
Use the following procedures to remove the brush.
1. Remove the cover A.
  
  Fig 12: Identifying Cover A
2. Remove the cover B.
  
  Fig 13: Identifying Cover B
3. Disconnect the connection and remove the brush.
  
  Fig 14: Removing Brush From Connection
Remove the rectifier as follows.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Locating Rectifier Bolt
2. Remove the cover on terminal B.
  
  Fig 16: Locating Cover Of Terminal B
3. Remove the nuts of terminal B, then remove the rectifier.
  
  Fig 17: Locating Nut Of Terminal B