Generators & Regulators: Overhaul Subaru Baja I

OVERHAUL

Disassembly

1. Remove the 4 through-bolts (Scheme 8)
2. Heat the portion (A) of rear cover to 122°F (50°C) with heater drier. (Scheme 9)
3. Insert the tip of a flat-head screwdriver into the gap between the stator core and front cover. Pry them apart to disassemble. (Scheme 10) CAUTION: To prevent rotor damage when holding rotor with vise, insert aluminum plates or wood pieces on vise's contact surfaces.
4. Hold rotor with a vise and remove pulley nut. (Scheme 11)and (Scheme 12). CAUTION: Rectifier cannot withstand heat well. Finish below steps rapidly (less than three seconds).
5. Remove the ball bearing as follows: Remove bolt, then remove bearing retainer. (Scheme 13)Firmly install to bearing inner race an appropriate tool, such as a fit socket wrench. (Scheme 14) Push the ball bearing off the front cover using a press.
6. Remove bearing from rotor using a bearing puller. (Scheme 15) CAUTION: The rectifier cannot withstand heat well. Do not allow the 180-270 watt soldering bit to contact the terminals for more than 5 seconds at a time.
7. Unsolder connection between rectifier and stator coil to remove stator coil. (Scheme 16)
8. Remove IC regulator as follows: Remove screws that secure the IC regulator to the rear cover. (Scheme 17) Unsolder connection between IC regulator and rectifier to remove IC regulator. (Scheme 18)
9. Remove brush as follows: Remove cover A. (Scheme 19) Remove cover B. (Scheme 20) Separate brush from connection to remove. (Scheme 21)
10. Remove rectifier as follows: Remove bolts that secure rectifier. (Scheme 22) Remove terminal B's cover. (Scheme 23) Remove nut from terminal B. (Scheme 24) Remove rectifier.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Assembly

Assemble generator in reverse order of disassembly procedure.

1. Before assembling, press the brush down into the brush holder. Fix it in that position by passing a wire (A).08" (1 mm) diameter length 1.6-2" (4-5 cm) wire through the hole. (Scheme 25)
2. Install ball bearing using following steps: Set the ball bearing on the front cover. Securely install to the bearing outer race an appropriate tool, such as a fit socket wrench. Press the ball bearing into the specified position using a press. Install the bearing retainer.
3. Install the bearing (rear side) into the rotor shaft with a press. CAUTION: Grease should not be applied to rear bearing. Completely remove the oil if found on bearing box.
4. Heat the bearing box in the rear cover to 122-140°F (50-60°C). Then, press the rear bearing into the rear cover.
5. After reassembly, turn the pulley by hand to check that the rotor turns smoothly.

Scheme 25