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TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)
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STATOR REMOVAL PROCEDURE
1.Remove engine spark plug wire to prevent accidental kickback or starting.
2.With the 5/16” nut driver, remove the 4 sheet metal screws that hold the top cover to the control box. Remove the top cover.
3.Remove the 4 1/2” nuts and washers that anchor the control box to the stator frame. Two of the nuts also anchor the reactor. The reactor must be moved over to access the front left hand nut anchoring the control box. Be careful not to drop the washers into the machine.
4.Lift up the control box and unscrew the 4 rubber mounts. Set the control box onto the stator frame for the moment.
5.Pull apart the molex coupling that connects the stator to the wiring harness.
6.With the slot head screw driver, remove the 6 sheet metal screws that hold the control panel to the control box - 3 on each side. You may need to use the 5/16” end wrench on the engine side because of limited clear- ance. Pull the panel away from the control box.
7.With the 9/16” open end wrench, remove lead W2 (Black) from the output terminal. See Figure F.9 for location. With the diago- nal cutters, cut the cable tie that holds the two output leads together. Pull lead W2 back out of the way; screw the bolt back
into the output terminal hole loosely for reassembly. Set the control panel back on the control box and hold it in place with 1 sheet metal screw in each side.
8.Remove the brush holder assembly. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail. The cover will drop open on its bottom hinge. With the 1/4” nut driver, remove the 2 screws that hold the brush holder assembly in place. With the needle nose pliers, gently remove the black and the red wires. Set the brush holder aside. Pull the wires up into the control box.
9.Pull apart the molex coupling for the engine flywheel alternator. This is the single wire on the left side of the machine, running from the engine to the stator.
10.Disconnect lead W1 (Black) that connects to the reactor lead. Replace the nut, split- ring lock washer, and flat washer finger tight on the bolt for reassembly.
11.Slide the control panel and box assembly out of the machine cradle. Carefully pull the wire leads down through the box as you remove it. Note that the reactor is loose inside the box and may slide around.
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FIGURE F.9 - OUTPUT LEAD LOCATION
TIE WRAP |
W2 |
W1 |
OUTPUT |
TERMINALS |
