GENERATOR DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A00K1WO

      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. A00K26GE01
      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. A00JXD1E01
      Text in Illustration
      *a Hold
      A00JWY4 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. A00JTVQ

      Remove the nut and cord clip.

    2. A00K0LO

      Remove the 3 nuts and generator rear end cover.

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. A00JZ9V

      Remove the terminal insulator from the generator coil.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A00JUGT

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A00K23O

      Remove the 4 bolts.

    2. A00JZO2E01
      Text in Illustration
      *a Hold
      A00JWY4 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. A00K1O6E01

      Remove the generator washer.

    2. A00JTU3

      Remove the generator rotor.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A00JZQF

      Check that the 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. A00JVOA

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

    2. A00JX6FE01

      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 )