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F-57

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL

AND REPLACEMENT (continued)

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12.With the 3/8” wrench and slot head screw driver, remove the four mounting screws (two on each side). Note the placement of the nylon insulators. These must be in place when you reinstall the rectifier bridge assembly in order to electrically insulate the bridge from the choke lam- ination assembly.

13.Remove the rectifier assembly by tilting it up and lifting it toward the front of the machine.

14.Reassembly: Refer to the Wiring Diagram for proper connections to the positive and negative sides of the rectifier assembly. The two sides of the bridge are marked + and -, respectively.

NOTE: Use Dow Corning 340 on all aluminum electrical connection surfaces.

15.With the 3/8” wrench and slot head screw driver, install the four mounting screws (two on each side). Note the placement of the nylon insulators. These must be in place when you install the rectifier bridge assembly in order to electrically insulate the bridge from the choke lam- ination assembly.

16.With the 7/16” socket wrench, install the S2 lead and the heavy lead going to the S1 Range switch. Note the order of fasteners: flat washer at the bottom followed by pig- tails, heavy leads, flat washer, lock wash- er, and nut.

17.With the 7/16” socket wrench, install the W1 lead and the heavy lead going to the S2 Polarity switch. Note the order of fas- teners: flat washer at the bottom followed by pigtails, heavy leads, flat washer, lock washer, and nut.

18.With the 1/2” socket wrench, install the heavy cable and the #8 lead (Blue) to the rectifier negative heat sink. Note the order of fasteners: bolt and flat washer from the bottom up through the heat sink; on top, leads, flat washer, lock washer, and nut.

19.With the 1/2” socket wrench, install the choke lead and the #10 lead (Blue) to the rectifier positive heat sink. Note the order of fasteners: bolt and flat washer from the bottom up through the heat sink; on top, leads, flat washer, lock washer, and nut.

20.Reinstall the case side, fuel cap, lift bail gasket, case top, and spark plug wire.