Alternator Overhaul: Overhaul

NOTE: Refer to the EXPLODED VIEW as needed during this procedure

Test the alternator and regulator before you remove them (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING )
Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION )

If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B) If necessary, use an impact wrench

Fig 1: Removing Pulley Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the three flange nuts

Fig 2: Identifying Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the end cover (A) and the terminal insulator (B)

Fig 3: Identifying End Cover And Terminal Insulator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder assembly (A)

Fig 4: Identifying Brush Holder Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the four through bolts, then remove the rear housing assembly (A) and the washer (B)

Fig 5: Identifying Rear Housing Assembly And Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are not replacing the front bearing, go to step 11 Remove the rotor from the drive-end housing

Fig 6: Identifying Drive-End Housing And Rotor
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks
- If the rotor is damaged, replace the rotor assembly
- If the rotor is OK, go to step 10
Remove the front bearing retainer

Fig 7: Identifying Front Bearing Retainer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive out the front bearing with a brass drift and a hammer

Fig 8: Driving Front Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the attachment, 42 x 47 mm

Fig 9: Installing Front Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Alternator Brush Inspection
Measure the length of both brushes (A) with a vernier caliper (B)
- If either brush is shorter than the service limit, replace the brush holder assembly
- If the brush length is OK, go to step 14
Alternator Brush Length

Standard (New) 10 5 mm (0 41 in)

Service Limit. 1 5 mm (0 06 in)

Fig 10: Measuring Length Of Brushes
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rotor Slip Ring Test
Check for continuity between the slip rings (A)
- If there is continuity, go to step 15
- If there is no continuity, replace the rotor assembly
Fig 11: Identifying Rotor, Rotor Shaft And Slip Rings
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C)
- If there is no continuity, replace the rear housing assembly, and go to step 16
- If there is continuity, replace the rotor assembly
Alternator Reassembly
If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 110 N m (11 2 kgf m,81 0 lbf ft)
Remove any grease or any oil from the slip rings
Put the rear housing assembly and the drive-end housing/rotor assembly together, tighten the four through bolts
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1 6 mm (0 06 in) diameter) to hold them there

Fig 12: Inserting Pin Or Drill Bit
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the brush holder assembly, and pull out the pin or drill bit

Fig 13: Pulling Pin Or Drill Bit
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the end cover
After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise
Install the alternator (see INSTALLATION ) and the drive belt (see DRIVE BELT REPLACEMENT )