The brushes are located under the rear of the generator casing or end plate. To replace the brushes, you will need a soldering iron, as well as an accurate measuring device to determine the remaining length of the brushes. For the latter, a caliper is most preferable.
Use only rosin for soldering, otherwise the joint will corrode.
Carbureted Accord and Prelude
1. Remove the generator.
2. On the other side of the pulley, remove the nuts and the generator cover.
3. Remove the insulator from the brush holder.
4. Remove the mounting screws from the brush holder and remove the holder.
5. Use a thickness gauge or calipers to determine the remaining length of the brushes. Permissible brush lengths for different models:
- ACCORD: New brush length: 10.5 mm. Minimum for worn brush: 5.5 mm.
- PRELUDE: New brush length: 15.5 mm. Minimum for worn brush: 5.3 mm.
6. Brushes that are worn down to almost their minimum length should be replaced.
7. Unsolder the brush connections and remove them.
Installing brushes:
8. Solder the new brushes in place of the old ones. Make sure the soldering is strong.
9. Install the brush holder and secure with screws.
10. Install the back cover and protective cover, if removed.
11. Install the generator.
Carburetor Prelude
1. Remove the generator.
2. On the other side of the pulley, remove the mounting bolts from the rear cover of the generator and remove it.
3. Remove the stator and diode assembly.
4. Measure the remaining length of the brushes with a thickness gauge or calipers. Acceptable brush sizes: new - 15.5 mm; minimum length of worn brush - 5.3 mm.
5. When the brush wears down to a size close to the minimum, it must be replaced.
6. After unsoldering the brush connections, remove them.
Installing brushes:
7. Solder the brushes in place of the old ones and make sure the soldering is strong.
8. Install the diode assembly and stator. Make sure the insulating washers are snapped into place.
9. Install the rear cover and terminal insulators.
10. Install the generator.