GENERATOR (for 100A Type) DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A01DLYR

      Using a screwdriver, remove the generator pulley cap.

  2. REMOVE GENERATOR WITH CLUTCH PULLEY


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

    2. A01DM91E01
      Text in Illustration
      *1 Rotor Shaft

      Install SST (A) and SST (B) to the generator with clutch pulley as shown in the illustration.

      SST
      09820-63021

      Note

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    3. A01DOGQE01
      Text in Illustration
      *a Hold
      A01DQPB Turn

      Use a wrench to hold SST (A) and turn SST (B) counterclockwise to loosen the generator with clutch pulley.

      Note

      Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    4. Remove SST from the generator.

    5. Remove the generator with clutch pulley from the rotor shaft.

  3. REMOVE GENERATOR REAR END COVER


    1. A01DM3W

      Remove the 3 nuts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR


    1. A01DOSI

      Remove the terminal insulator.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01DTGF

      Remove the 2 screws and generator brush holder.

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A01DNK8

      Remove the 4 through bolts.

    2. A01DPF1E02
      Text in Illustration
      *a Hold
      A01DQPB Turn

      Using SST, remove the generator coil.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )

  7. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A01DSTS

      Remove the washer.

    2. A01DTD2

      Remove the generator rotor from the generator drive end frame.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A01DS5X

      Check that the generator drive end frame bearing is not rough or worn.

      If necessary, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A01DOAE

      Remove the 4 screws and retainer plate.

    2. A01DRPWE01

      Using SST and a hammer, tap out the generator drive end frame bearing.

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )