Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Bench Testing: Brushes
Remove voltage regulator from back of generator. See VOLTAGE REGULATOR under REMOVAL & INSTALLATION. Ensure brushes are longer than 0.20" (5 mm). If necessary, install new brushes. DO NOT allow solder to run into strands of brush leads. See Fig 1 and Fig 2 .
| Application | In. (mm) |
|---|---|
| New | 0.5 (12) |
| Wear Limit | 0.2 (5) |
| Tolerance | 0.04 (1) |
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.