GENERATOR DISASSEMBLY


  1. REMOVE GENERATOR REAR END COVER


    1. B000K76

      Remove the 3 nuts and generator rear end cover.

  2. REMOVE GENERATOR TERMINAL INSULATOR


    1. B000M45

      Remove the generator terminal insulator from the generator coil.

  3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. B000K0S

      Remove the 2 screws and brush holder from the generator coil.

  4. REMOVE GENERATOR COIL ASSEMBLY


    1. B000IFG

      Remove the 4 bolts.

    2. B000MIKE09
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the generator coil assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
    3. B000N5TE01

      Remove the generator washer.

  5. REMOVE GENERATOR CLUTCH PULLEY


    1. B000I9M

      Using a screwdriver, remove the generator pulley cap.

      Note

      Do not reuse the generator pulley cap.

    2. Mount the generator drive end frame in a vise tightly.

    3. B000N6TE04
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

      Confirm SST (A) and (B) shown in the illustration.

      SST
      09820-63021
    4. B000MRAE03
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. B000HPZE02
      Text in Illustration
      *1 Clutch Pulley
      *2 SST (B)
      *3 SST (A)

      Fit SST (B) to the clutch pulley.

    6. B000J5TE02
      Text in Illustration
      *1 SST (B)
      *2 SST (A)

      Loosen the pulley by turning SST (B) in the direction shown in the illustration.

      Note


      • Check that the drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    7. Remove SST from the generator assembly.

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

  6. REMOVE GENERATOR ROTOR ASSEMBLY


    1. B000INTE01

      Remove the generator rotor assembly.

  7. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. B000IK1

      Check that the bearing is not rough or worn.

      OK
      The bearing rotates smoothly.

      If the bearing does not rotate smoothly, replace the bearing.

  8. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. B000JW2

      Remove the 4 screws and bearing retainer from the drive end frame.

    2. B000J00E01

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

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