Generator repair - Magneti Marelli

I found that a gear puller was not a good choice for me since the pulley is brittle. An expensive lesson.

Remove the nut and washer as you suggest. Squirt some penetrating oil down the shaft. Let sit for a while. Suspend the generator by the pulley a little above a padded landing place. Have an assistant smack the end of the shaft with the nut on the end with a soft head hammer. Some heat can help too. Once the shaft and pulley hole and key are cleaned of any rust I used a smear of anti-seize and the pulley slips right on and is easy to remove if there is a next time.

• Start by giving the head of the screw a good solid smack with a hammer, supporting the inside of course. Then soak the screws with your favorite penetrating oil for at least 24 hours. Heat can also be used, but you'll want to be careful about burning insulation and the coil wrap (if you aren't re-wrapping...I always rewrap).
• I've had mixed luck using a large Phillips bit from a hand impact screwdriver. The one I have fits nicely in my ¹⁄₂ inch breaker bar. Then I support the main body of the generator in my drill press vice. With the breaker bar in place, I bear down on top of the breaker bar with the drill press, then rotate the breaker bar. Sometimes it works and the screw pops loose. Sometimes the slots in the screw simply shear off. The good news is that universal replacements of the screws used on these generators are readily available. So, if one does foul on you, drill it out and replace it with a new one.

1. The bolts are too long and will interfere with the rotating the armature. I reduced the length using my bench grinder.
2. The head of the bolts is too large and too thick. It will sit proud of the generator body and interfere with the generator bracket. I reduced the overall height (and diameter) using my bench grinder.