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OUTPUT
TERMINALS
W1
W2
TIE WRAP
FIGURE F.16 – OUTPUT LEAD LOCATION
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)
STATOR REMOVAL PROCEDURE
1. Remove engine spark plug wire to prevent acci-
dental kickback or starting.
2. With the 5/16” nutdriver, remove the 4 sheet
metal screws that hold the top cover to the con-
trol box. Remove the top cover.
3. Remove the 4 1/2” nuts and washers that
anchor the control box to the stator frame. Two
of the nuts also anchor the reactor. The reactor
must be moved over to access the front left
hand nut anchoring the control box. Be careful
not to drop the washers into the machine.
4. Lift up the control box and unscrew the 4 rubber
mounts. Set the control box onto the stator
frame for the moment.
5. Pull apart the molex coupling that connects the
stator to the wiring harness.
6. With the slot head screw driver, remove the 6
sheet metal screws that hold the control panel
to the control box - 3 on each side. You may
need to use the 5/16” end wrench on the engine
side because of limited clearance. Pull the
panel away from the control box.
7. With the 9/16” open end wrench, remove lead
W2 (Black) from the output terminal. See
Figure F.16 for location. With the diagonal cut-
ters, cut the cable tie that holds the two output
leads together. Pull lead W2 back out of the
way; screw the bolt back into the output termi-
nal hole loosely for reassembly. Set the control
panel back on the control box and hold it in
place with 1 sheet metal screw in each side.
8. Remove the brush holder assembly. Open the
brush holder assembly cover. Squeeze the 2
tabs and depress the cover at the top with a
screw driver or your fingernail. The cover will
drop open on its bottom hinge. With the 1/4”
nutdriver, remove the 2 screws that hold the
brush holder assembly in place. With the
needlenose pliers, gently remove the black and
the red wires. Set the brush holder aside. Pull
the wires up into the control box.
9. Pull apart the molex coupling for the engine fly-
wheel alternator. This is the single wire on the
left side of the machine, running from the
engine to the stator.
10. Disconnect lead W1 (Black) that connects to
the reactor lead. Replace the nut, split-ring
lock washer, and flat washer finger tight on the
bolt for reassembly.
11. Slide the control panel and box assembly out of
the machine cradle. Carefully pull the wire
leads down through the box as you remove it.
Note that the reactor is loose inside the box
and may slide around.
TROUBLESHOOTING AND REPAIR
F-45 F-45
BULLDOG® 140
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