Generator Fix
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The seal was still in good condition.  It just popped back in with finger pressure.  You could use a tiny tiny tiny bit of Loctite or Permatex on the outside of the seal but be extremely careful.  The tiniest bit of sealant can get into a roller bearing and start jamming a ball, making it skate instead of roll.  The entire bearing will melt soon after.  It gets really ugly then because the generator is gear driven and it will either seize the motor or break off the gear and then it could get really exciting.  Don't glue your bike together.  Silicone and gasket sealant cause horrible damage in a roller bearing engine.  If seal won't pop in then use a large socket the size of the seal and our friendly rubber mallet to tap it in.

Meth-amphetamine addicts: STOP NOW.  Take generator to qualified service personnel.  You will only mash the seal into a ball of useless rubber as you use a 2 pound sledge or, worse yet, you will glob silicone all over the seal that will get into the motor and seize all the roller bearings..
Assembly is essentially the reverse of disassembly-- good luck, see ya.

Ha ha, just kidding.  We try to be a little more helpful then the factory manual.  Tap the armature in with a small rubber mallet.  Note that the vise is opened way up and gently tightened on the protruding rings of the end bell.  You aren't supposed to use sandpaper to shine up the copper commutator because the grit gets stuck in the soft copper and then grinds up the brushes prematurely.  You aren't supposed to break the speed limit or wear illegal helmets either and I do that too.  The armature lathe I bought on e-bay isn't here yet.

Meth-amphetamine addicts: STOP NOW.  Take generator to qualified service personnel.  You will ruin the bearing surface by bashing with a two pound sledge.  You will tighten the vise on one side of the armature and hammer on the other side.  It will get ruined.  It always does.  Get wise.

It's usually easier to put the brush plate on after the frame is installed.  This plate was too snug to pop out so the handle of the mallet was used to gently tap it free.  You can leave the wire attached but don't get too rude with it.  I also was using paper towels to dry off any oil on the parts.

Meth-amphetamine addicts: STOP NOW.  Take generator to qualified service personnel.  An ox acetylene cutting torch will not help in removing the plate and will have serious personal liability and property damage consequences.
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