Alternator Overhaul: Disassembly

NOTE: Refer to the Exploded View if needed during this procedure.

Alternator End Cover
1. Remove the end cover (A).
  
  Fig 1: Identifying Alternator End Cover
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Brush Holder
1. Remove the brush holder assembly.
Fig 2: Identifying Alternator Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Brush - Inspection
1. 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.
  
  Alternator Brush Length
  
  Standard (New): 10.5 mm(0.41 in)
  
  Service Limit: 1.5 mm(0.06 in)
  
  Fig 3: Measuring Alternator Brush Length Using Vernier Caliper
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Rear Housing Assembly
1. Remove the rear housing assembly.
Fig 4: Identifying Alternator Rear Housing Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Pulley
1. 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 5: Removing Alternator Pulley Locknut Using Wrench
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Rotor
1. Remove the drive-end housing.
Fig 6: Identifying Alternator Rotor
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Rotor Slip Ring - Test
1. Check for continuity between the slip rings (A).
2. Check for continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C).
  If there is continuity, replace the rotor assembly.
  
  Fig 7: Identifying Alternator Rotor Slip Ring, Rotor And Shaft
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Front Alternator Bearing
1. Remove the front bearing retainer.
  
  Fig 8: Identifying Front Alternator Bearing
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Remove the front bearing.
Fig 9: Removing Front Bearing Using Tool
Courtesy of AMERICAN HONDA MOTOR CO., INC.