Help! I removed the brushes to check the length and this black plastic stepped washer fell out onto the floor. Am I right that the plastic washer goes over the left side brush holder against the stator face and the two fork terminals go over the narrow part? If this is correct when I put the screw back in the terminals are loose. What am I missing? Thanks!
The that round,black plastic part is one of the insulators and it looks like you might be missing the special hold-down screw w/ washers that holds the brush/holder assembly onto the generator case.
yeah there's a washer as stated that goes over that that shoulders the insulator. you can use a nylon one as well
So this is what I have (first pic). The screw has a lock washer and a metal flat washer. I'm assuming there should be another insulator to isolate the wires from grounding. I will follow your suggestion and use a nylon one (second pic). Will this work? Thanks!
2nd pic
yes thats it. as long as it mashes the 2 big flag connectors together between the insulted washers, it will work if not, might need 2 nylon washers. . Remember, that's the wire that powers the alternator rotor on and off from the voltage regulator so it def needs to make a good solid connection.
Thanks M in SC, I did as you suggested. Now I think I have a further problem. With ignition switch on should I see voltage at the green wire (positive brush) and the stator become magnetized? I have nothing so I suspect there is no current going to the brush and hence generator is not doing anything which would explain why the battery is not getting charged.
prob need to check the points in the voltage regulator.