Generators & Regulators: Overhaul: Alternator: Reassembly

1. If you removed the pulley, put the rotor in the drive-end housing. Tighten locknut to specification. See TORQUE SPECIFICATIONS .
2. Remove any grease or any oil from the slip rings.
3. Push the brushes "A" in. Insert a pin or drill bit "B".77" (1.8 mm diameter) to hold them there. See Fig 1.
4. Heat the rear bearing seat with a 1,000 watt hair dryer for about 5 minutes (129-140°F (50-60°C).
5. Put the rear housing assembly "A" and drive-end housing/rotor assembly "B" together, tighten the four through bolts "C" and pull out the pin "D". See Fig 2.
6. After assembling the alternator, turn the pulley by hand to ensure the rotor rotates smoothly and without noise.
7. Install the alternator and drive belt. See ALTERNATOR  and DRIVE BELT  under REMOVAL & INSTALLATION.

Fig 1: Retaining Brushes In Installation Position

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Reassembling Alternator

Courtesy of AMERICAN HONDA MOTOR CO., INC.