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ROTOR
STATOR
FEELER GAUGE
FIGURE F.19 – CHECKING ROTOR-STATOR AIR GAP
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)
6. Install the bottom two end bracket thru-bolts.
NOTE: The flat washer goes on the top right hand
thru-bolt for the green ground wire.
7. Tap the end bracket with the mallet as neces-
sary to position it. Tighten the bolts to 22 - 25 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 move-
ment and alignment.
8. Check the rotor-stator air gap with the long .010
feeler gauge. The measurement is taken
through the brush holder access door; see
Figure F.19. 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 measure again. If the gauge does
not clear, loosen the four end bracket thru-bolts,
reposition the end bracket, retighten the bolts,
and recheck the air gap. Repeat until the prop-
er .010 minimum air gap is achieved.
9. Tighten the end bracket support nuts and lock
washers. Remove the 2 X 4 engine support.
10. Reinstall the brush holder assembly. Refer to
the topic “BRUSH REMOVAL AND
REPLACEMENT” in this section of the manual.
11. Slide the control box back into place. Pull the
stator and ground wire up through.
12. Remove the control panel (2 screws) and
reconnect the output terminal leads (W1, W2).
Install a new cable tie to hold the leads togeth-
er. Reconnect the stator wire/harness molex
coupling. Install the 6 screws that hold the con-
trol panel to the box.
13. Connect the engine flywheel alternator cou-
pling.
14. Lift the control box and screw in the rubber
mountings. Set the control box onto the
mountings.
15. Install the front left hand washer and nut that
anchors the control box to the stator frame.
Position the reactor and install the remaining
washers and nuts.
16. Check all terminal connections for clearance,
grounding, and tightness.
17. Replace the top cover to the control box and
tighten the 4 nuts.
18. Conduct the “RETEST AFTER REPAIR” pro-
cedure, the following topic in this section of the
manual.
TROUBLESHOOTING AND REPAIR
F-48 F-48
BULLDOG® 140
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