Disassembly and Reassembly
DisassemblyNOTE: Insert protective material in the jaws of the vise.
1. Remove four cap screws from rear housing.
2. Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear housing.
NOTE: If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear housing fit together very tightly
3. Use a flat-blade screwdriver to separate front housing from stator.
NOTE: Be careful not to lose the stopper spring that fits around the rear bearing.
NOTE: Insert protective material in the jaws of the vise.
4. Place rotor in a vise and loosen locknut, then disassemble pulley, rotor, and front housing.
5. If necessary, remove front bearing using a socket and a hand press or vise.
6. Remove rear bearing with a bearing puller.
7. Remove B terminal nut and insulating bushing.
8. Remove five screws holding the rectifier and brush holder.
9. Separate rear bracket and stator.
10. Use a soldering iron to remove solder from rectifier and stator leads, and then remove IC regulator.
NOTE: Disconnect quickly If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat
11. Replace brushes. Remove solder from pigtail, and then remove brush.
Reassembly
1. Assemble brush, and solder pigtail so that wear limit line of brush projects 0.079 - 0.118 in (2 - 3 mm) out of brush holder.
2. Assemble regulator, and solder with rectifier and stator leads.
NOTE: Disconnect quickly If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat
3. Assemble rear bracket and stator.
4. Tighten screws holding rectifier and brush holder.
Tightening torque: 1.5 - 4.0 lb-ft (2.0-5.4 N.m, 0.2-0.55 kg-m)
5. Tighten B terminal nut and insulating bushing.
6. Assemble rear bearing and stopper spring.
NOTE: Make sure groove on bearing rim is facing slip ring side.
7. Assemble front bearing. Using a socket which exactly fits outer race of bearing, carefully push in front bearing. Use a hand press or a vise.
NOTE: Insert protective material in the jaws of the vise.
8. Place rotor in a vise, assemble front housing and tighten locknut.
Tightening torque: 43 - 72 lb-ft (59 - 98 N.m)
9. Assemble rear housing and tighten four cap screws.
Tightening torque: 2.1 - 4.7 lb-ft (2.9 - 6.4 N.m, 0.3 - 0.65 kg-m)