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TROUBLESHOOTING & REPAIR
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)
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6.Double check that the spark plug wires are disconnected. You will be turning the rotor during this procedure, and this could cause engine kickback.
7.Hold the rotor shaft with locking pliers. With the 5/8" wrench or an impact wrench, remove the rotor
8.Remove the
9.Install the appropriate long
10.Turning it counterclockwise, screw in the
11.If the rotor does not pop off, continue to carefully prevent the rotor shaft from turning and tighten the rotor removal tool an addi- tional 5 ft lbs. until the rotor pops off the engine crankshaft.
12.With the 7/16" wrench, remove the side fire- walls.
13.With the 9/16" wrench, remove the four bolts that hold the stator to the engine. There is one lock washer per bolt.
14.Carefully remove the stator/rotor assembly from the engine. Once the assembly is sep- arated from the engine, be careful that the rotor does not fall out of the stator.
15.Carefully remove the rotor from the stator. You can tap carefully on the end of the rotor shaft with a rubber mallet. Guide the rotor carefully to prevent damage to its core.
REASSEMBLY NOTES
Reassemble the rotor and stator to the Ranger 250 by carefully retracing the disassembly proce- dure steps in reverse order. Keep the following special points in mind as you proceed. A Lead Reconnection Checklist is provided here to aid in reassembly.
Rotor/Stator/Engine Reassembly
Refer to Figure F.30.
NOTE: Lincoln Electric recommends that you install a new bearing (Lincoln part
1.Fit the rotor into the stator, being careful not to damage the rotor core against the stator. Position the rotor so that the laminations are at top and bottom and air gap at the sides. This will limit movement of the rotor.
IMPROPER HANDLING OF THE ROTOR CAN RESULT IN SHORTED WINDINGS AND/OR LOST OUTPUT.
2.Tap the rotor carefully with a mallet to fit the bearing all the way into the stator frame.
3.Clean the tapered engine crankshaft.
4.Using the hoist, carefully fit the stator/rotor assembly onto the engine crankshaft.
5.Install the four bolts that mount the stator to the engine. NOTE: Apply Loctite 271 thread sealant to the two bottom bolts on the ONAN engine, to prevent oil leakage from the crankcase. With the 9/16" wrench, draw the bolts up evenly in order to seat the rotor bearing properly. Tighten moving diagonal- ly from bolt to bolt.
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