Overhaul

Disassembly:

1. Remove the four through-bolts

   Alternator rear cover heating

2. Using a heated drier, heat portion (A) of rear cover to 50 °C (122 °F)
3. Insert a flat tip screwdriver into the gap between stator core and front cover, and carefully, pry them apart

   Alternator exploded view

4. Using a vise to hold the rotor, remove the pulley nut

   CAUTION
   Take care while holding the rotor with vise, use aluminum plates or wood pieces to insert on the contact surfaces of vise to prevent damaging rotor

5. Removing ball bearing is as follows
   • To remove retainer, remove the bearing retainer bolt
   • Install a tool (such as a socket of the same size) to inner bearing race.
   • Using a press, push the bearing off the front cover

     Bearing puller

   • Using a bearing puller, (as shown in the picture) remove the bearing from the rotor

   Unsolder connections

   CAUTION
   Do not allow the solding bit to contact the terminals for more than 5 seconds at a time because the rectifier cannot withstand heat for long periods.

6. Using a 180 - 270 W solding bit, unsolder connection between rectifier and stator coil to remove same
7. The IC regulator is removed as follows
   • Remove IC regulator to rear cover screws
   • Unsolder IC regulator to rectifier connection
8. Remove the brush as follows

   Unsolder connections

   Unsolder connections

   • Remove cover’s A and B as shown in the pictures
   • Separate the brush from connection
9. Remove the rectifier as follows.
   • Remove the rectifier mounting bolts

     Rectifier nut and cover

   • Remove the rectifier terminal cover and nut

Assembly:

1. Install the rectifier as follows
   • terminal cover and nut
   • Install the rectifier mounting bolts
2. Install the brush as follows
   • Connect the brush
   • Install covers A and B
   • Pulling up brush before assembling, press the brush down into brush holder, and then fix them in that position by passing a [1 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire through the hole shown in the picture

   CAUTION
   Be sure to remove the wire after reassembly.

3. Re-Solder IC Regulator To Rectifier Connection
4. Install IC regulator to rear cover screws

   CAUTION
   Do not allow the solding bit to contact the terminals for more than 5 seconds at a time because the rectifier cannot withstand heat for long periods.

5. Using a 180 - 270 W solding bit, solder connection between rectifier and stator coil to install same
6. Install the ball bearing as follows
   • Setting the ball bearing on the front cover, install a tool (such as a socket of the same size) to outer bearing race
   • Using a press, install the bearing into the specified position
   • Install the bearing retainer
   • Using a press, install the bearing (rear side) into the rotor shaft
7. Using a heated drier, heat portion A (as shown in previous picture) of rear cover to 50 °C (122 °F) and press the rear bearing into the rear cover

   CAUTION
   Do not apply grease to the rear bearing. Completely remove any oil if it is found on bearing box.

8. Using A Vise To Hold The Rotor, Install The Pulley Nut

   CAUTION
   Take care while holding the rotor with vise, use aluminum plates or wood pieces to insert on the contact surfaces of vise to prevent damaging rotor

9. Install the four through-bolts
10. After reassembly, turn the pulley by hand to check that rotor turns smoothly.