Attention! We carry out the work on an inspection pit or lift.
Remove the oil pan protection plate and the right engine mudguard (see Removal the oil pan protection plate and splash guard of a carburetor engine).
Remove the coolant pump drive belt (see Adjusting the tension and replacing the coolant pump drive belt).
Using pliers, loosen the clamp on the rubber air intake.
We remove the air intake from the generator protective casing pipe.
We disconnect the output "61" of the generator.
After moving the rubber cover, use a 10 mm wrench to unscrew the nut securing the wires to the generator terminal extension "30".
We remove the wires.
Using a 17 mm socket head, unscrew the nut securing the generator to the tension bar.
Using a 19 mm open-end wrench, unscrew the nut securing the generator to the bracket..
…and remove the bolt.
We remove the generator from the engine compartment downwards.
A rubber and metal bushing are installed in the eye of the rear cover of the generator.
Using a 10 mm spanner, unscrew the nut of the insulating sleeve of the generator terminal extension cable "30".
We remove the outer…
…and internal insulating bushings.
Using a slotted screwdriver, unscrew the two screws securing the protective casing to the generator.
We remove the protective cover.
Disconnect the wire from terminal "61".
Using a 10 mm spanner, unscrew the extension piece for the 30 mm terminal.
We remove the extension cord.
Disconnect the wire from the voltage regulator.
Using a Phillips screwdriver, unscrew the two screws securing the voltage regulator and brush holder.
We remove the voltage regulator with the brush holder.
Using a 19 mm wrench, unscrew the generator pulley nut. The rotor can be locked from turning with a screwdriver (do not bend the impeller).
We remove the washer from the shaft,…
…pulley halves,…
…spacer washer,…
…the impeller.
We pry it up with a screwdriver and remove the segment key,…
…under which there is a washer without a keyway.
Using a 10 mm spanner, unscrew the nut securing the capacitor terminal.
We remove the terminal and, having unscrewed the screw with a Phillips screwdriver, we dismantle the capacitor.
Using a sharp scriber or paint, mark the relative positions of the covers and the stator for subsequent assembly.
Using a 10 mm socket head, unscrew the four nuts of the tie bolts.
We take out the bolts.
Remove the front cover.
To replace the bearing, use an 8 mm spanner to unscrew the four nuts securing the plates from the outside of the cover.
We remove the plates with screws.
With a tool head of the appropriate size (or a piece of pipe) we press the bearing out of the cover.
There is a thrust ring on the rotor shaft.
We screw a nut onto the shaft thread, clamp it in a vice and with a jerk remove the back cover with the stator.
If you have difficulty removing the rotor, tap its end with a soft metal punch through the voltage regulator window.
We disconnect the rotor and stator.
Using a puller, we press the bearing off the rotor shaft.
Using an 8 mm socket head, unscrew the three nuts securing the stator terminals to the rectifier unit.
We pry it up with a screwdriver and remove the stator.
We remove the rectifier block.
We remove the contact bolt from the rectifier block.
We assemble the generator in the reverse order. We put the nuts of the screws of the bearing plates of the front cover on the thread sealant. We press new bearings into the front cover and onto the rotor shaft with suitable pipe sections.