Service Manual

11
Brush – Inspect/Repair/Replace
The carbon brush is located behind the cover of
the alternator.
Remove bolts (3) and remove motor cover (4).
Check the length of the brushes (5). If the length
is 7 mm or less, replace the brush. To remove
the brush, remove bolts (1) and disconnect the
leads. To reinstall, connect the red lead to the
“+” terminal, the white lead to the “-” terminal,
then use the bolts (1) to secure the new brush.
Check the contact surface between the brush (2)
and the collector ring. If the contacting surface
appears to be less than 75% of the brush
surface, resurface the brush. Put emery cloth
between the brush and the collector ring with the
grit side facing the brush. Work the emery cloth
back and forth against the brush until there is
more than 75% contact area. Do not just spin
the collector as a charge may build in the
windings. Remove any debris from the generator
before reassembling.
Camshaft – Inspect/Replace
Inspect the camshaft for damage or abnormal
wear. Measure the lift on the camshaft lobes.
The acceptable limits for the lift are shown in the
table below. If the lift is out of the acceptable
range, replace the camshaft.
Model: Lobe:
Normal
Lift:
Minimum
Lift:
RP1200E
Intake 18.006mm 17.940mm
Exhaust 18.006mm 17.940mm
Measure the outside diameter of the camshaft.
The acceptable limits for the diameter are shown
in the table below. If the diameter is out of the
acceptable range, replace the camshaft.
Model: Normal: Minimum:
RP1200E 13.275mm 13.225mm
5