Separate alternator from engine (small power generator)

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  • OVERALL DIFFICULTY INDEX: 6/10
  • IF YOU HAVE NO TOOLS, YOU PAY $75 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 4 HOURS TO CARRY OUT THIS JOB
  • RISK OF HAND INJURY, SEE BELOW​
BEFORE YOU START
  • Your engine should be cold for this intervention. Do not attempt to work on a hot engine.
  • Watch out when unscrewing the alternator bolts, they could loosen suddenly sending your hand onto a hard or sharp surface resulting in an injury.
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.
Note: the below works are widely compatible with any of the KAMA and KIPOR KDE5000, KDE5500, KDE6000 and KDE6500 generators.

How to remove (extract) the alternator from the engine crank

1- Cut the cable ties that hold the wire bundles to the alternator legs.
2- Unplug all connectors.  
3- Unscrew the two bolts that hold the alternator crown.
4- Take it out and leave it. Do not disconnect the stator wires.
5- Remove the brushes holder now or any time before step 12.
6- Prepare to loosen the rotor bolt.
7- Block the engine by inserting long nose pliers in the flywheel fins.   
8- Unscrew the rotor bolt and then the stator bolts (4).
9- Remove the nuts that hold the alternator legs.
10- Lift it upwards and insert a wooden piece to keep it away from the frame.
11- Place the extractor. Make sure it is well centered. Rotate the axle until the stator comes out.
12- Put is aside.
13- Hit the rotor with a 1-2 Kg hammer and a piece of wood in between. 
14- One short and firm hit will bring it out of its conical coupling.
15- Complete the operation by unscrewing and removing the alternator fan housing.

Check out available Kama / Kipor spares at our partners' stores:

See also other tips for generator repair: