Starting/Charging (H4SO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Locating 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 flattip screwdriver into the gap between stator core and front cover. Separate these to disassemble.

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

Fig 4: Removing Pulley Bolt

CAUTION: Insert the aluminum plate or wood piece into the contact surface of the vise while support the rotor in the vise to prevent damaging the rotor.

Fig 5: Identifying Front Cover, Pulley, Nut And Rotor
Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 6: Identifying Bearing Retainer Bolt
2. Firmly install the appropriate tool (such as the right size of socket wrench) to the bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
3. Use the press to push the ball bearings from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Removing Bearings From Rotor Using Bearing Puller
Disconnect the connection between the rectifier and stator coil, then remove the stator coil.
CAUTION: Do not touch it with 180 to 270 W solder on its terminals for more than 5 seconds consecutively, because the rectifier cannot withstand so much heat.

Fig 9: Removing Stator Coil
Use the following procedures to remove the IC regulator.
1. Remove the screws which secure IC regulator to the rear cover.
  
  Fig 10: Identifying IC Regulator Screws
2. Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
Fig 11: Disconnecting 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
Use the following procedures to remove the rectifier.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Identifying Rectifier Bolt
2. Remove the cover on the terminal B.
  
  Fig 16: Locating Cover Of Terminal B
3. Remove the nuts of the terminal B, then remove the rectifier.
Fig 17: Identifying Rectifier Terminal Nut B