GENERATOR DISASSEMBLY


  1. INSPECT GENERATOR WITH VACUUM PUMP ASSEMBLY


    1. Mount the generator in a vise between aluminum plates.

    2. A01DQ4I

      Insert a screwdriver to hold the generator rotor.

    3. Install a bolt and nut to the outside of the pulley so that the bolt head and nut clamp the pulley, and then position a dial indicator as shown in the illustration.

    4. Turn the pulley and measure the backlash between the generator rotor and vacuum pump shaft.

      Maximum backlash
      1.6 mm (0.0630 in.)

      If the backlash is more than the maximum, replace the generator rotor and vacuum pump shaft.

  2. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DTUPE01
      Text in Illustration
      *a Matchmark

      Place matchmarks as shown in the illustration.

    2. Remove the 4 bolts and vacuum pump.

  3. REMOVE GENERATOR REAR END COVER


    1. A01DMIX

      Remove the nut and terminal insulator.

    2. Remove the bolt, 3 nuts, rectifier plate and rear end cover.

  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. Remove the brush holder cover.

    2. A01DN7J

      Remove the 2 screws and brush holder.

    3. Remove the plate seal.

  5. REMOVE GENERATOR REGULATOR ASSEMBLY


    1. A01DUKF

      Remove the 3 screws and generator regulator.

  6. REMOVE GENERATOR HOLDER WITH RECTIFIER


    1. A01DPPN

      Remove the 4 screws and generator holder with rectifier.

    2. Remove the 4 rubber insulators.

  7. REMOVE GENERATOR RECTIFIER END FRAME


    1. A01DN24E01
      Text in Illustration
      *1 Cord Clip

      Remove the 4 nuts and cord clip.

    2. A01DQP8E01
      Text in Illustration
      *a Hold
      A01DQPB Turn

      Using SST, remove the rectifier end frame.

      SST
      09286-46011

    3. Remove the washer from the rotor.

  8. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A01DUPWE01

      Using SST and a press, press out the rotor.

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )