Please make sure it really needs to be overhauled first, see troubleshooting your KISS. Check the U-Tube video on “how to test the rectifier”. If you have any questions call me. My cell phone is (727) 638-1248. There are minor differences in the newer, made in the USA KISSes. How to overhaul a KISS wind generator:
Completely remove the screws
Insert screwdriver/pry bar only 1/2 inch. Note the slight angle. A little chipping is bound to occur.
The screwdriver can go in more deeply in this area
You can remove the front bearing with a wood block and hammer. DO NOT LET THE HAMMER HIT THE MAGNET – IT WILL SHATTER, SENDING PIECES INTO YOUR EYES (wear eye protection whenever using a hammer).
Install the bearings with the install tool ( a short 7/8 inch pipe). Make sure the bearing is all the way on. Do not hit the outter bearing race.
Remove any flakes of metal plating and lightly sand any rust. Treat with “Rust Reformer” or similar.
If there is none, drill a small (~3/32 in.) hole from where the bottom of the bearing will rest, downward and out the front cover. This allows any water that gets past the front seal to drain.
install a new seal
The new screws have an acorn nut and are easier to work with. However, there is not enough room for a socket around the nut.
Using a 1/2 inch “bur”, you can open up the area around the screw head, like so:
opened Install the bearing seats with the ends up. If yours are black in color, replace them with the translucent white ones.
unsolder the thermostats, and solder the new ones in (including the wire terminals)
place the stator into the housing, using a screw to properly locate it
Install the rotor – CAUTION – IT WILL GO IN ALL OF A SUDDEN, DO NOT HAVE YOUR FINGERS BELOW THE BEARING!
Use a soft hammer to insert the rear bearing into the bearing seat.
When the rear bearing is in the seat, the stator metal frame will be near the front cover mating surface, like so. Push the front cover down as far as it will go. Install the new screws and evenly tighten them.
Check to make sure the shaft turns freely. Hit the shaft with a soft hammer to seat the bearings evenly. Measure the turning torque with a string and fish scale. It should turn at 8- 10 pounds. Apply tape as shown, and then apply 3M 4000 or your favorite goo. Remove the tape before the goo dries, and smooth with your finger. Lightly sand and paint the housing with Rustolium white. Call us for new decals.