GENERATOR DISASSEMBLY

  1. REMOVE GENERATOR REAR END COVER

    1. Remove the 3 nuts and generator rear end cover.

      A011SIX

  2. REMOVE GENERATOR TERMINAL INSULATOR

    1. Remove the generator terminal insulator from the generator coil.

      A011VB2

  3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

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

      A011US4

  4. REMOVE GENERATOR COIL ASSEMBLY

    1. Remove the 4 bolts.

      A011RPJ

    2. Using SST, remove the generator coil assembly.

      A011QREE09
      Text in Illustration
      *a Turn
      *b Hold
      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )

    3. Remove the generator washer.

      A011QPXE01

  5. REMOVE GENERATOR PULLEY WITH CLUTCH

    1. Using a screwdriver, remove the generator pulley cap.

      A011UEV

      Note

      Do not reuse the generator pulley cap.

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

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

      A011T6HE04
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      SST
      09820-63021

    4. Place the rotor shaft end into SST (A).

      A011UL3E03
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

    5. Fit SST (B) to the generator pulley with clutch.

      A011RP8E02
      Text in Illustration
      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)

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

      A011QV7E02
      Text in Illustration
      *1 SST (B)
      *2 SST (A)

      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. Remove the generator rotor assembly.

      A011S3IE01

  7. INSPECT GENERATOR DRIVE END FRAME BEARING

    1. Check that the bearing is not rough or worn.

      A011SDX
      OK
      The bearing rotates smoothly.

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

  8. REMOVE GENERATOR DRIVE END FRAME BEARING

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

      A011RU5

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

      A011SVUE01
      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )