Alternator - Disassembly (75 A Model)

1. Remove the three through bolts.

2. Insert a flat-blade screwdriver between the front alternator bracket and the stator, and use the screwdriver as a lever to separate the front alternator bracket (downward).

1. Do not insert the screwdriver too deeply, to avoid damaging the stator coil.

2. It may be difficult to remove the rear alternator bracket because the snap ring used to retain the rear bearing gets in the way.

To make removal of the rear bracket easier, heat the bearing assembly with a 200 W soldering iron.

Do not use a heat gun for heating, as this may damage the rectifier diodes.

3. Secure the rotor in a vise with the pulley side facing up.

Make sure the vise jaws do not damage the rotor.

4. Remove the pulley nut, remove the spring washer, then remove the pulley and spacer.

5. Remove the front alternator bracket and the two O-rings.

6. Remove the rotor from the vise.

7. Remove the screws securing the brush holder and rectifier. Then remove the "B" terminal nut.

8. Remove the stator assembly from the rear bracket. 9. Remove the dust seal ring from the brush holder.

10. Before removing the stator, unsolder the three stator coil wires from the main rectifier diodes.

1. When soldering/unsoldering the terminals, be careful to minimize heat transfer from the soldering iron to the diodes. Perform these operations as quickly as possible.

2. Be careful not to apply excessive force to the diode terminals.

11. Before disconnecting the rectifier from the brush holder, unsolder the two terminals soldered to the rectifier.