Starting System & Charging System (H6DO): Generator: Disassembly

Remove four bolts.

Fig 1: Locating Generator Assembly Bolts
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Use a drier to heat the rear cover (A) portion to 50 - 60°C (122 - 140°F).

Fig 2: Heating Rear Cover
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Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Flat Tip Screwdriver Into Gap
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Using a vise, support the rotor and remove the pulley nut, then remove the rotor from the front cover.
CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Fig 4: Removing Pulley Nut
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Fig 5: Identifying Front Cover, Rotor, Pulley And Pulley Nut
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Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 6: Locating Ball Bearing Retainer Bolts
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2. Set an appropriate tool (such as a socket wrench of proper size) properly to the bearing inner race.
  
  Fig 7: Setting Socket To Bearing Inner Race
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3. Use the press to push the ball bearings out from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Removing Bearings From Rotor
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Remove six bolts between the rectifier and stator coil, then remove the stator coil.

Fig 9: Locating Stator Coil Bolts
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Remove four screws which secure the IC regulator to the rear cover, then remove the IC regulator.

Fig 10: Locating IC Regulator Screws
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Use the following procedures to remove the brush.
1. Remove the cover A.
  
  Fig 11: Identifying Cover A
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2. Remove the cover B.
  
  Fig 12: Identifying Cover B
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3. Disconnect the connection and remove the brush.
Fig 13: Disconnecting Brush
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Remove the rectifier as follows.
1. Remove the cover on terminal B.
  
  Fig 14: Locating Terminal B Cover
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2. Remove the nut on terminal B.
  
  Fig 15: Locating Terminal B Nut
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3. Remove the bolts which secure the rectifier, and remove the rectifier.
Fig 16: Locating Rectifier Bolts
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