GENERATOR (for 80A Type) INSPECTION


  1. INSPECT GENERATOR WITH CLUTCH PULLEY


    1. A009A8V

      Hold the center of the generator with clutch pulley and confirm that the outer ring turns counterclockwise and does not turn clockwise.

      Text in Illustration
      A009BSG Free
      A009710 Lock

      If the result is not as specified, replace the generator with clutch pulley.

  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0096ZNE01
      Text in Illustration
      *1 Length

      Using a vernier caliper, measure the brush length.

      Standard exposed length
      9.5 to 11.5 mm (0.374 to 0.453 in.)
      Minimum exposed length
      4.5 mm (0.177 in.)

      If the brush length is less than the minimum, replace the generator brush holder assembly.

  3. INSPECT GENERATOR REGULATOR ASSEMBLY


    1. A009BSJE01
      Text in Illustration
      *1 Terminal F
      *2 Terminal B

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      Terminal F - Terminal B Always Below 1 Ω or higher than 10 kΩ

      If the result is not as specified, replace the generator regulator assembly.

      Tech Tips

      When the ohmmeter leads are initially touched to the regulator, one of the above values is output.

      When the leads are reversed, the reading changes to the other value.

    2. A00988KE01
      Text in Illustration
      *1 Terminal F
      *2 Terminal E

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      Terminal F - Terminal E Always Below 1 Ω or higher than 10 kΩ

      If the result is not as specified, replace the generator regulator assembly.

      Tech Tips

      When the ohmmeter leads are initially touched to the regulator, one of the above values is output.

      When the leads are reversed, the reading changes to the other value.

  4. INSPECT GENERATOR HOLDER WITH RECTIFIER


    1. Inspect the positive (+) rectifier.


      1. A0096CQE01
        Text in Illustration
        *1 Positive (+) Terminal
        *2 Rectifier Terminal

        Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Check that one polarity shows a resistance of below 1 Ω and the other shows a resistance of 10 kΩ or higher.

        If the result is not as specified, replace the generator holder with rectifier.

    2. Inspect the negative (-) rectifier.


      1. A009705E01
        Text in Illustration
        *1 Negative (-) Terminal
        *2 Rectifier Terminal

        Using an ohmmeter, connect one tester probe to the negative (-) terminal and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Check that one polarity shows a resistance of below 1 Ω and the other shows a resistance of 10 kΩ or higher.

        If the result is not as specified, replace the generator holder with rectifier.

  5. INSPECT GENERATOR ROTOR ASSEMBLY


    1. Check the generator rotor for an open circuit.


      1. A009AULE01
        Text in Illustration
        *1 Slip Ring

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Slip ring - Slip ring 20°C (68°F) 1.7 to 2.1 Ω

        If the result is not as specified, replace the generator rotor assembly.

    2. Check if the generator rotor is grounded.


      1. A0095LQE01
        Text in Illustration
        *1 Slip Ring
        *2 Coil Core

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Slip ring - Rotor core Always 10 kΩ or higher

        If the result is not as specified, replace the generator rotor assembly.

    3. Inspect the slip rings.


      1. Check that the slip rings are not rough or scored.

        If the slip lings are rough or scored, replace the generator rotor assembly.

      2. A009BVIE01
        Text in Illustration
        *1 Diameter

        Using a vernier caliper, measure the slip ring diameter.

        Standard diameter
        14.2 to 14.4 mm (0.559 to 0.567 in.)
        Minimum diameter
        14.0 mm (0.551 in.)

        If the diameter is less than the minimum, replace the generator rotor assembly.