• HEADINGS
  • Component Location Index & Drive Belt Routing
  • Symptom Troubleshooting Index
  • Circuit Diagram
    • '04-05 models
    • '06-08 models
  • Charging System Indicator Circuit Troubleshooting
    • '04-05 models
    • '06-08 models
  • Alternator and Regulator Circuit Troubleshooting
  • Alternator Control Circuit Troubleshooting
  • Drive Belt Inspection
  • Drive Belt Replacement
  • Drive Belt Auto-tensioner Inspection
  • Drive Belt Auto-tensioner Replacement
  • Tensioner Pulley Replacement
  • Alternator Removal and Installation
    • Removal
    • Installation
  • Alternator Overhaul
    • Exploded View
    • Special Tools
    • Overhaul
• FIGURES
  • Fig. 1: Identifying Charging System Component Location Index & Drive Belt Routing
  • Fig. 2: Charging System - Circuit Diagram (04-05 Models)
  • Fig. 3: Charging System - Circuit Diagram (06-08 Models)
  • Fig. 4: Measuring Voltage Between Alternator 4P Connector Terminal No. 1 And Body Ground
  • Fig. 5: Checking Continuity Between ECM/PCM Connector Terminal B10 And Alternator 4P Connector Terminal No. 3
  • Fig. 6: Checking Continuity Between ECM/PCM Connector Terminal B10 And Body Ground
  • Fig. 7: Checking Continuity Between ECM/PCM Connector Terminal B10 And Body Ground
  • Fig. 8: Connecting Alternator 4P Connector Terminal No. 3 And Body Ground With Jumper Wire
  • Fig. 9: Checking Continuity Between ECM/PCM Connector Terminal Bio And Alternator 4P Connector Terminal No. 3
  • Fig. 10: Connecting Vat-40 And Turning Selector Switch
  • Fig. 11: Measuring Voltage Between Alternator 4P Connector Terminal No. 2 And Positive Terminal Of Battery
  • Fig. 12: Checking Continuity Between ECM/PCM Connector Terminal B18 And Body Ground
  • Fig. 13: Checking Continuity Between ECM/PCM Connector Terminal B18 And Alternator 4P Connector Terminal No. 2
  • Fig. 14: Identifying Auto-Tensioner Indicator
  • Fig. 15: Moving Auto-Tensioner
  • Fig. 16: Identifying Auto-Tensioner Indicator
  • Fig. 17: Moving Auto-Tensioner
  • Fig. 18: Clamping Auto-Tensioner
  • Fig. 19: Identifying Auto-Tensioner Bolt Tightening Angle
  • Fig. 20: Identifying Power Steering (P/S) Pump Bolts w/Torque Specifications
  • Fig. 21: Identifying Auto-Tensioner And Bolts w/Torque Specifications
  • Fig. 22: Identifying Tensioner Pulley With Bolt w/Torque Specifications
  • Fig. 23: Identifying Alternator Connector And BLK Wire
  • Fig. 24: Identifying Alternator Bolts
  • Fig. 25: Identifying Alternator Bolts w/Torque Specifications
  • Fig. 26: Identifying Alternator Connector And BLK Wire w/Torque Specifications
  • Fig. 27: Exploded View Of Alternator Overhaul
  • Fig. 28: Removing Pulley Locknut
  • Fig. 29: Identifying Harness Stay And Three Flange Nuts
  • Fig. 30: Identifying End Cover
  • Fig. 31: Identifying Brush Holder
  • Fig. 32: Identifying Rear Housing Assembly And Bolts
  • Fig. 33: Identifying Rotor
  • Fig. 34: Identifying Front Bearing Retainer
  • Fig. 35: Removing Front Bearing
  • Fig. 36: Installing Front Bearing
  • Fig. 37: Checking Alternator Brush Length
  • Fig. 38: Checking Continuity Between Slip Rings
  • Fig. 39: Inserting Pin Or Drill Bit
  • Fig. 40: Pulling Out Pin
• TABLES
  • SYMPTOM TROUBLESHOOTING CHART

2004-08 ELECTRICAL

Charging System - TSX

Component Location Index & Drive Belt Routing

Fig. 1: Identifying Charging System Component Location Index & Drive Belt Routing
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Symptom Troubleshooting Index

SYMPTOM TROUBLESHOOTING CHART

Symptom	Diagnostic procedure
Charging system indicator does not come on with the ignition switch ON (II)	Troubleshoot the charging system indicator circuit '04-05 models (see '04-05 MODELS ), '06-08 models (see '06-08 MODELS ).
Charging system indicator stays on	Check for PGM-FI DTCs (see GENERAL TROUBLESHOOTING INFORMATION ). Troubleshoot the charging system indicator circuit '04-05 models (see '04-05 MODELS ), '06-08 models (see '06-08 MODELS ). Check for a broken drive belt (see DRIVE BELT INSPECTION ). Check the drive belt auto-tensioner (see DRIVE BELT AUTO-TENSIONER INSPECTION ).
Battery discharged	Check for excessive parasitic electrical current draw with the ignition switch OFF, and the key removed. The multiplex control unit may take up to 10 minutes to turn off (sleep mode) for some models. Check for a broken drive belt (see DRIVE BELT INSPECTION ). Check the drive belt auto-tensioner (see DRIVE BELT AUTO-TENSIONER INSPECTION ). Troubleshoot the alternator and regulator circuit (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ). Check for a poor connection at the battery terminal. Test the battery (see BATTERY TEST ).
Battery overcharged	Troubleshoot the alternator and regulator circuit (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ). Test the battery (see BATTERY TEST ).

Circuit Diagram

'04-05 models

Fig. 2: Charging System - Circuit Diagram (04-05 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

'06-08 models

Fig. 3: Charging System - Circuit Diagram (06-08 Models)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Charging System Indicator Circuit Troubleshooting

'04-05 models

1. Turn the ignition switch ON (II).

   Does the charging system indicator come on?

   YES -Go to step 2.

   NO -Go to step 3.

2. Start the engine.

   Does the charging system indicator go off?

   YES -Charging system indicator circuit is OK. Go to the ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING .

   NO -Go to step 3.

3. Do the gauge control module self-diagnostic function procedure (see SELF-DIAGNOSTIC FUNCTION ).

   Does the charging system indicator flash?

   YES -Go to step 4.

   NO -Replace the gauge control module (see GAUGE CONTROL MODULE REPLACEMENT ).

4. Turn the ignition switch OFF.
5. Disconnect the alternator 4P connector.
6. Turn the ignition switch ON (II).
7. Measure the voltage between alternator 4P connector terminal No. 1 and body ground.

   Fig. 4: Measuring Voltage Between Alternator 4P Connector Terminal No. 1 And Body Ground
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Is there battery voltage?

   YES -Go to step 8.

   NO -Check for a blown No. 18 (15 A) fuse in the under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the alternator and under-dash fuse/relay box.

8. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM) ). Turn the ignition switch ON (II), and jump the SCS line with the HDS, then turn the ignition switch OFF.

   NOTE:

   This step must be done to protect the engine control module (ECM)/powertrain control module (PCM) from damage.

9. Disconnect ECM/PCM connector B (24P).
10. Check for continuity between ECM/PCM connector terminal B10 and alternator 4P connector terminal No. 3.

    Fig. 5: Checking Continuity Between ECM/PCM Connector Terminal B10 And Alternator 4P Connector Terminal No. 3
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Go to step 11.

    NO -Repair open in the wire between the alternator and the ECM/PCM.

11. Check for continuity between ECM/PCM connector terminal B10 and body ground.

    Fig. 6: Checking Continuity Between ECM/PCM Connector Terminal B10 And Body Ground
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Repair short in the wire between the alternator and the ECM/PCM.

    NO -Go to the ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING .

'06-08 models

1. Turn the ignition switch ON (II).

   Does the charging system indicator come on?

   YES -Go to step 2.

   NO -Go to step 14.

2. Start the engine. Hold the engine speed at 2,000 rpm for 1 minute.

   Does the charging system indicator go off?

   YES -Charging system indicator circuit is OK. Go to the ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING .

   NO -Go to step 3.

3. Do the gauge control module self-diagnostic function procedure (see SELF-DIAGNOSTIC FUNCTION ).

   Does the charging system indicator flash?

   YES -Go to step 4.

   NO -Replace the gauge control module (see GAUGE CONTROL MODULE REPLACEMENT ).

4. Turn the ignition switch OFF.
5. Disconnect the alternator 4P connector.
6. Turn the ignition switch ON (II).

   NOTE:

   The charging system indicator may come on and then go off.

   Does the charging system indicator go off?

   YES -Replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ), or repair the alternator (see ALTERNATOR OVERHAUL ).

   NO -Go to step 7.

7. Turn the ignition switch OFF.
8. Connect the HDS to the DLC.
9. Turn the ignition switch ON (II).
10. '07-08 models: Make sure the HDS communicates with the vehicle and the ECM/PCM. If it doesn't communicate, troubleshoot the DLC circuit (see '07-08 MODELS ).
11. Jump the SCS line with the HDS, then turn the ignition switch OFF.

    NOTE:

    This step must be done to protect the ECM/PCM from damage.

12. Disconnect ECM/PCM connector B (24P).
13. Check for continuity between ECM/PCM connector terminal B10 and body ground.

    Fig. 7: Checking Continuity Between ECM/PCM Connector Terminal B10 And Body Ground
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Repair short in the wire between the alternator and the ECM/PCM.

    NO -Update the ECM/PCM if it does not have the latest software (see UPDATING THE ECM/PCM ), or substitute a known-good ECM/PCM (see SUBSTITUTING THE ECM/PCM ), then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM, '04-05 models (see '04-05 MODELS ), '06-08 models (see '06-08 MODELS ).

14. Do the gauge control module self-diagnostic function procedure (see SELF-DIAGNOSTIC FUNCTION ).

    Does the charging system indicator flash?

    YES -Go to step 15.

    NO -Replace the gauge control module (see GAUGE CONTROL MODULE REPLACEMENT ).

15. Turn the ignition switch OFF.
16. Disconnect the alternator 4P connector.
17. Connect alternator 4P connector terminal No. 3 and body ground with a jumper wire.

    Fig. 8: Connecting Alternator 4P Connector Terminal No. 3 And Body Ground With Jumper Wire
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Turn the ignition switch ON (II).

    Does the charging system indicator come on?

    YES -Replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ), or repair the alternator (see ALTERNATOR OVERHAUL ).

    NO -Disconnect the jumper wire, then go to step 19.

19. Turn the ignition switch OFF.
20. Connect the HDS to the DLC (see step 2 on HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM) ).
21. Turn the ignition switch ON (II).
22. '07-08 models: Make sure the HDS communicates with the vehicle and the ECM/PCM. If it doesn't communicate, troubleshoot the DLC circuit (see '07-08 MODELS ).
23. Jump the SCS line with the HDS, then turn the ignition switch OFF.

    NOTE:

    This step must be done to protect the ECM/PCM from damage.

24. Disconnect ECM/PCM connector B (24P).
25. Check for continuity between ECM/PCM connector terminal BIO and alternator 4P connector terminal No. 3.

    Fig. 9: Checking Continuity Between ECM/PCM Connector Terminal Bio And Alternator 4P Connector Terminal No. 3
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Update the ECM/PCM if it does not have the latest software (see UPDATING THE ECM/PCM ), or substitute a known-good ECM/PCM (see SUBSTITUTING THE ECM/PCM ), then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM, '04-05 models (see ECM/PCM REPLACEMENT ), '06-08 models (see '06-08 MODELS ).

    NO -Repair open in the wire between the alternator and the ECM/PCM.

Alternator and Regulator Circuit Troubleshooting

1. Make sure the battery connections are good and the battery is fully charged (see BATTERY TEST ).
2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting).

   Fig. 10: Connecting Vat-40 And Turning Selector Switch
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Start the engine. Hold the engine speed at 3,000 rpm with no load (in the N or P position (A/T) or the N position (M/T)) until the radiator fan comes on, then let it idle.
4. Raise the engine speed to 2,000 rpm, and hold it there.

   Is the voltage over 15.1 V?

   YES -Replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ) or replace the rear housing assembly (see ALTERNATOR OVERHAUL ).

   NO -Go to step 5.

5. Release the accelerator pedal, and let the engine idle.
6. Turn off all the accessories. Select the charging test on the tester.
7. Remove the inductive pickup, and zero the ammeter.
8. Place the inductive pickup over the B terminal wire of the alternator so the arrow points away from the alternator.
9. Raise the engine speed to 2,000 rpm, and hold it there.

   Is the voltage less than 13.5 V?

   YES -Go to ALTERNATOR CONTROL CIRCUIT TROUBLESHOOTING .

   NO -Go to step 10.

10. Apply a load with the VAT-40 until the battery voltage drops to between 12 and 13.5 V.

    Is the amperage 60 A or more?

    YES -The charging system is OK.

    NOTE:

    If the charging system indicator is still on, replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ) or replace the rear housing assembly (see ALTERNATOR OVERHAUL ).

    NO -Replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ) or repair the alternator (see ALTERNATOR OVERHAUL ).

Alternator Control Circuit Troubleshooting

1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM) ).
2. Turn the ignition switch ON (II).
3. '07-08 models: Make sure the HDS communicates with the vehicle and the engine control module (ECM)/powertrain control module (PCM). If it doesn't communicate, troubleshoot the DLC circuit (see '07-08 MODELS ).
4. Check for DTCs (see GENERAL TROUBLESHOOTING INFORMATION ). If a DTC is present, diagnose and repair the cause before continuing with this test.
5. Disconnect the alternator 4P connector from the alternator.
6. Start the engine, and turn on the headlights to high beam.
7. Measure the voltage between alternator 4P connector terminal No. 2 and the positive terminal of the battery.

   Fig. 11: Measuring Voltage Between Alternator 4P Connector Terminal No. 2 And Positive Terminal Of Battery
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Is there 1 V or less?

   YES -Go to step 11.

   NO -Go to step 8.

8. Jump the SCS line with the HDS, then turn the ignition switch OFF.

   NOTE:

   This step must be done to protect the ECM/PCM from damage.

9. Disconnect ECM/PCM connector B (24P).
10. Check for continuity between ECM/PCM connector terminal B18 and body ground.

    Fig. 12: Checking Continuity Between ECM/PCM Connector Terminal B18 And Body Ground
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Repair short in the wire between the alternator and the ECM/PCM.

    NO -Update the ECM/PCM if it does not have the latest software (see UPDATING THE ECM/PCM ), or substitute a known-good ECM/PCM (see SUBSTITUTING THE ECM/PCM ), then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM, '04-05 models (see ECM/PCM REPLACEMENT ), '06-08 models (see '06-08 MODELS ).

11. Jump the SCS line with the HDS, then turn the ignition switch OFF.

    NOTE:

    This step must be done to protect the ECM/PCM for damage.

12. Disconnect ECM/PCM connector B (24P).
13. Check for continuity between ECM/PCM connector terminal B18 and alternator 4P connector terminal No. 2.

    Fig. 13: Checking Continuity Between ECM/PCM Connector Terminal B18 And Alternator 4P Connector Terminal No. 2
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity?

    YES -Replace the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ) or repair the alternator (see ALTERNATOR OVERHAUL ).

    NO -Repair open in the wire between the alternator and the ECM/PCM.

Drive Belt Inspection

1. Inspect the belt for cracks or damage. If the belt is cracked or damaged, replace it.
2. Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If it is out of the standard range, replace the drive belt (see DRIVE BELT INSPECTION ).

   Fig. 14: Identifying Auto-Tensioner Indicator
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Drive Belt Replacement

Special Tools Required

Belt tension release tool Snap-on YA9317 or equivalent, commercially available

1. Move the auto-tensioner (A) using the belt tension release tool to relieve tension from the drive belt (B), and remove the drive belt.

   Fig. 15: Moving Auto-Tensioner
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Install the new belt in the reverse order of removal.

   NOTE:

   For belt routing, see COMPONENT LOCATION INDEX & DRIVE BELT ROUTING.

Drive Belt Auto-tensioner Inspection

Special Tools Required

Belt tension release tool Snap-on YA9317 or equivalent, commercially available

1. Check whether there is a change in the position of the auto-tensioner indicator before starting the engine and after starting the engine. If there is a change in the position, replace the auto-tensioner.

   Fig. 16: Identifying Auto-Tensioner Indicator
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Check for abnormal noise from the tensioner pulley. If you hear abnormal noise, replace the tensioner pulley (see TENSIONER PULLEY REPLACEMENT ).
3. Remove the drive belt (see DRIVE BELT INSPECTION ).
4. Move the auto-tensioner within its limit using the belt tension release tool in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. If the tensioner does not move smoothly, or you hear abnormal noise, replace the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).

   Fig. 17: Moving Auto-Tensioner
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).
6. Clamp the auto-tensioner (A) by using two 8 mm bolts (B) and a vise (C) as shown. Do not clamp the auto-tensioner itself.

   Fig. 18: Clamping Auto-Tensioner
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Fig. 19: Identifying Auto-Tensioner Bolt Tightening Angle
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Set the torque wrench (D) in the pulley bolt in the direction shown.
8. Align the indicator (E) on the tensioner base with center mark (F) on the tensioner arm by using the torque wrench, and measure the torque. If the torque value is out of specification, replace the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).

   NOTE:

   If the indicator exceeds the center mark, recheck the torque.

   Auto-tensioner Spring Torque:

   32.5-39.7 N.m (3.31-4.05 kgf.m, 24.0-29.3 lbf.ft)

Drive Belt Auto-tensioner Replacement

1. Remove the drive belt (see DRIVE BELT INSPECTION ).
2. Remove the power steering (P/S) pump without disconnecting the P/S hoses.

   Fig. 20: Identifying Power Steering (P/S) Pump Bolts w/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the auto-tensioner.

   Fig. 21: Identifying Auto-Tensioner And Bolts w/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the auto-tensioner in the reverse order of removal.

Tensioner Pulley Replacement

1. Remove the drive belt (see DRIVE BELT INSPECTION ).
2. Remove the pulley bolt (A), then remove the tensioner pulley (B).

   Fig. 22: Identifying Tensioner Pulley With Bolt w/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Install the tensioner pulley in the reverse order of removal.

Alternator Removal and Installation

Removal

1. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
2. Disconnect the negative cable from the battery.
3. Remove the drive belt (see DRIVE BELT INSPECTION ).
4. Remove the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).
5. Disconnect the alternator connector (A) and BLK wire (B) from the alternator.

   Fig. 23: Identifying Alternator Connector And BLK Wire
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Remove the three bolts securing the alternator, then remove the alternator.

   Fig. 24: Identifying Alternator Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Installation

1. Install the three bolts securing the alternator.

   Fig. 25: Identifying Alternator Bolts w/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Connect the alternator connector (A) and BLK wire (B) to the alternator. Make sure the crimped side of the ring terminal faces away from the starter when you connect it.

   Fig. 26: Identifying Alternator Connector And BLK Wire w/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Install the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).
4. Install the drive belt (see DRIVE BELT INSPECTION ).
5. Connect the negative cable to the battery.
6. Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the audio presets. Set the clock (on vehicles without navigation).

Alternator Overhaul

Exploded View

Fig. 27: Exploded View Of Alternator Overhaul
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools

Special Tools Required

• Handle driver 07749-0010000
• Attachment, 42 x 47 mm 07746-0010300

Overhaul

NOTE:

Refer to the EXPLODED VIEW as needed during this procedure.

1. Test the alternator and regulator before you remove them (see ALTERNATOR AND REGULATOR CIRCUIT TROUBLESHOOTING ).
2. Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
3. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.

   Fig. 28: Removing Pulley Locknut
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the harness stay and the three flange nuts from the alternator.

   Fig. 29: Identifying Harness Stay And Three Flange Nuts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the end cover.

   Fig. 30: Identifying End Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Remove the brush holder.

   Fig. 31: Identifying Brush Holder
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the four bolts, then remove the rear housing assembly (A), and washer (B).

   Fig. 32: Identifying Rear Housing Assembly And Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. If you are not replacing the front bearing, go to step 13. Remove the rotor from the drive-end housing.

   Fig. 33: Identifying Rotor
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.
   • If the rotor is damaged, replace the rotor assembly.
   • If the rotor is OK, go to step 10.
10. Remove the front bearing retainer.

    Fig. 34: Identifying Front Bearing Retainer
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Drive out the front bearing with a brass drift and hammer.

    Fig. 35: Removing Front Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Install a new front bearing in the drive end housing with a hammer, the handle driver, and attachment.

    Fig. 36: Installing Front Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Alternator Brush Inspection

13. Measure the length of both brushes (A) with a vernier caliper (B).
    • If either brush is shorter than the service limit, replace the brush holder assembly.
    • If the brush length is OK, go to step 14.

    Alternator Brush Length:

    Standard (New): 10.5 mm (0.410 in.)

    Service Limit: 1.5 mm (0.060 in.)

    Fig. 37: Checking Alternator Brush Length
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Rotor Slip Ring Test

14. Check for continuity between the slip rings (A).
    • If there is continuity, go to step 15.
    • If there is no continuity, replace the rotor assembly.

      Fig. 38: Checking Continuity Between Slip Rings
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

15. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
    • If there is no continuity, replace the rear housing assembly, and go to step 16.
    • If there is continuity, replace the rotor assembly.

    Alternator Reassembly

16. If you removed the pulley, put the rotor in the drive-end housing, then tighten its lock nut to 110 N.m (11.2 kgf.m, 81.0 lbf.ft).
17. Remove any grease or oil from the slip rings.
18. Put the rear housing assembly and drive-end housing/rotor assembly together, then tighten the four through bolts.
19. Push in the brushes (A), then insert a pin or drill bit (B) (about 1.6 mm (0.06 in.) diameter) to hold them there.

    Fig. 39: Inserting Pin Or Drill Bit
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Install the brush holder, then pull out the pin.

    Fig. 40: Pulling Out Pin
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Install the end cover.
22. After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise.
23. Install the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ) and drive belt (see DRIVE BELT INSPECTION ).