1988 Precis (with Bosch generator)
1. Remove the generator.
17.2 Remove the two mounting screws to remove the voltage regulator/brush holder (indicated by arrows) and remove the brush holder
2. Loosen the fixing screws of the voltage regulator (17.2).
17.3 Measure the length of the brushes with a small ruler - if they are shorter than 2-3 mm, replace them
3. Remove the brush holder and measure the length of the brushes. If they are shorter than 4.6mm, replace them. (17.3)
17.4 To remove worn brushes from the holder, carefully desolder the wires of the brushes
4. Desolder the brush wires (17.4) and remove the brushes and springs.
5. Installation is carried out in the reverse order of removal. Solder new brushes securely.
All other models (with Melco generator)
6. Remove the generator.
7. Remove the bolts securing the halves of the generator.
8. Clamp the front of the generator in a vise.
9. Turn off all nuts from a back side of the generator.
17.10a To facilitate disassembly of the generator, heat the bearing housing
1. Soldering iron; 2. Bearing housing
10. Use a powerful soldering iron to heat the back box (17.10a
17.10b Using two screwdrivers, separate the halves of the generator and, using two screwdrivers, wring out the rear casing
17.11 Melco generator elements
1. Alternator pulley; 2. Oil seal; 3. Rotor; 4. Rear bearing; 5. Bearing mounting; 6. Front bearing; 7. Front bracket; 8. Stator; 9. Terminal; 10. Plate; 11. Regulator and brush holder; 12. Brush; 13. Brush spring; 14. Sleeve; 15. Restorer; 16. Rear bracket; 11. Desolder the brush holder/regulator (17.11)
17.12a If the brushes are worn beyond the limit line, they must be replaced
1. limit line; 2. limit line
17.12b When replacing the brushes, solder the wires at the following points
1. Solder
12. Inspect brushes and replace if necessary (17.12a and 17.12b).
17.13 When installing new brushes, they must protrude from the holder by a certain amount
13. When installing new brushes, solder the ends of the brush wires so that the brushes protrude from the holder by 1.9-2.9 mm (17.13).
17.14 When joining the two halves together, pull the wire through the back cover and brush holder to secure the brushes in the holder
1. Wire; 2. Brush; 3. Wire
14. Assembly is carried out in the reverse order of disassembly (17.14).