You can separate the removal of the brushes and the regulator.
Bosch generator
1. Remove ground wire from battery.
2. Unscrew the 3 screws and remove the heat shield.
3. Unscrew the 2 screws securing the voltage regulator and, being careful, remove the regulator.
4. Check the length of the graphite brushes (distance A), which must be at least 5 mm.
5. To replace the carbon brushes, it is necessary to unsolder the current leads, remove the worn brushes and springs, install new brushes with springs in the regulator socket and solder the current lead so that the length of the brushes is 10 mm. When soldering, do not allow flux and solder to get on the current lead, except for the place of soldering (1 - brushes, 2 - brush pressure springs, 3 - brush holder).
6. Check the ease of movement of the brushes in the holder.
Lucas Generator
1. Remove ground wire from battery.
2. Remove heat shield.
3. Remove the wire connector from the generator.
4. Unscrew the back cover of the generator.
5. Disconnect the wires from the regulator, unscrew the connecting plate, the regulator fixing screw and remove the regulator (1 - screw, 2 - plastic gasket, 3 - connecting plate, 4 - regulator).
6. unscrew the screws (indicated by an arrow) attaching the graphite brushes and remove the brushes from the holder.
7. Check the length of the graphite brushes, which must be at least 5 mm.
Motorola Generator
1. Remove ground wire from battery.
2. Remove heat shield.
3. Remove the wire connector from the generator.
4. Unscrew the regulator (A) and disconnect 2 wires (indicated by arrows).
5. Unscrew the screw securing the brush holder.
6. Unscrew the brush holder and, carefully turning it outward, remove it from the generator (1 - graphite brush, 2 - contact).
7. Check the length of the graphite brushes, which must be at least 4 mm.
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