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| TROUBLESHOOTING AND REPAIR |
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
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6.Install the bottom two end bracket thru- bolts.
7.Tap the end bracket with the mallet as nec- essary to position it. Tighten the bolts to 4.5 - 5.5 ft lbs. Alternate tightening in order to pull the assembly together evenly. As you tighten, look through the brush housing access door and watch the bearing to judge end bracket movement and align- ment.
8.Check the
.010 feeler gauge. The measurement is taken through the brush holder access door; see Figure F14. Turn the engine with the recoil starter rope slightly so that the rotor “iron” is up to take the measurement. (The rotor has two flat sides, which are not measured for air gap.) Slide in the gauge. Then rotate the shaft 180 degrees and mea- sure again. If the gauge does not clear, loosen the four end bracket
9.Tighten the end bracket support nuts and lock washers. Remove the 2 X 4 engine support.
10.Position the control box into place.
11.Reinstall the brush holder assembly. Refer to the Brush Removal and Replacement
Procedure.12.Reconnect the output lead W2 to the output terminal.
13.Install a new cable tie to hold the leads together.
14.Reconnect the large molex plug.
15.Install the five sheet metal screws that secure the control box to the stator frame. Be sure to connect the green ground lead to the screw previously removed.
16.Reconnect the flashing lead #205 to diode D2. Secure lead in control box.
17.Using the 6 sheet metal screws previously removed, mount the control box panel to the control box.
18.Using the 1/2” wrench replace the 2 bolts and star washers securing the control box to the stator frame.
19.Carefully set the reactor in place and secure with the two remaining bolts and star wash- ers.
20.Reconnect the reactor leads.
21.Check all terminal connections for clear- ance, grounding, and tightness.
22.Replace the top cover to the control box and tighten the 8 screws.
23.Conduct the Retest After Repair Procedure.