Disassembly and Reassembly/Overhaul

Disassembled View

Disassembly
1. Terminal insulator and nut(2).




2. Remove three nuts(1) on the rear cover and a nut on terminal B and insulator, then remove the rear cover( 3).




3. Remove two screws that fix the brush holder(5) and rectifier, then remove the brush holder assembly(4).




4. Remove three screws on the IC regulator, then the IC regulator assembly(6).




5. Remove four screws that fix rectifier(7) and stator lead wires.




6. Secure the pulley directly in the vise between two copper plates, and remove the nut and pulley.




7. Remove four nuts(B) that secure the front cover assembly and rear end cover, and an insulator(9).
8. Use the puller to remove the rear end cover.




9. Rotor assembly




10. Pull the rotor assembly(10) off the front cover assembly(12) using a bench press(11).

Reassembly
To reassemble, follow the disassembly steps in the reverse order, noting the following points:




1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover.




2. Install pulley on the rotor.
Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque.

Torque: 111 N.m (82 lb.ft)