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TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE AND CHOKE
REMOVAL AND REPLACEMENT (continued)
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5.Using the 1/2" and 9/16" wrenches, hold and loosen the nut holding the engine choke cable to the back of the front panel. Pull the cable through the front panel. Save the sleeve and nut for reassembly.
6.With the 3/8" socket wrench, remove the four screws holding the front panel to the machine base. Tilt the front panel as far for- ward as the attached leads will permit. Cut any necessary cable ties.
7.With two 1/2" wrenches, remove heavy leads W6, W11 and W7 and their bolt, lock washers and flat washers from the negative strap on the right side of the output rectifier.
8.With two 1/2" wrenches, remove heavy leads W4 and W5 and their bolt, lock wash- ers and flat washers from the positive strap of the output rectifier.
9.With two 1/2" wrenches remove heavy leads W1, W2, and W3 and their bolts, lock washers and flat washers from the three straps on the left side of the output rectifier.
10.With the 1/2" wrench or socket wrench, remove the nuts and lock washers holding the output rectifier to the machine mounting bracket. You will need to reach through the large access holes on either side of the rec- tifier to place the wrench on these nuts.
11.Remove the output rectifier from the machine.
Output Choke
1.Remove the output rectifier as described above.
2.Using the 1/2" wrenches, remove the heavy flex leads W8, W9 and W10 from the choke.
3.Using the 1/2" wrenches, remove the three long bolts, lock washers, and nuts holding the choke to the mounting bracket in the machine base. Note that the lower right corner of the choke has no bolt.
4.Carefully remove the choke.
REPLACEMENT PROCEDURE
Output Choke
1.Place the choke into the machine so that the three mounting holes line up with the mounting holes in the machine mounting bracket.
2.Insert the three long bolts through the choke and the mounting bracket. Place a lock washer and nut on each bolt and tighten with the 1/2" wrenches.
3.Using the 1/2" wrenches, attach the heavy flex leads W8, W9 and W10 to the appropri- ate choke lead connections. See the Wiring Diagram.
Output Rectifier
1.Place the output rectifier into the machine so that its mounting studs fit into the holes in the bracket. Attach the nuts and lock washers using the 1/2" wrench.
2.Attach heavy leads W1, W2, and W3 to the three straps on the left side of the rectifier plates. See Figure F.25 for placement.
3.Attach heavy leads W4 and W5 to the posi- tive strap on the rectifier. See Figure F.25 for placement.
4.Attach heavy leads W6, W11 and W7 to the negative strap of the rectifier. See Figure F.25 for placement.
5.Attach the front panel to the machine base with four 3/8" screws. Replace any cable ties cut during removal.
6.Insert the engine choke cable through the case front, attach it with the 9/16" nut and install the sleeve. Fit the end of the cable into the hole in the choke control lever, then attach the cable to the choke control lever in the position noted at disassembly using its 5/16" clamp.
7.Perform the Case Cover Replacement pro- cedure.
