GENERATOR DISASSEMBLY


  1. INSPECT GENERATOR WITH VACUUM PUMP ASSEMBLY


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

    2. A009BMV

      Insert a screwdriver to hold the generator rotor.

    3. Install a bolt and nut to the outside of the pulley so that the bolt head and nut clamp the pulley, and then position a dial indicator as shown in the illustration.

    4. Turn the pulley and measure the backlash between the generator rotor and vacuum pump shaft.

      Maximum backlash
      1.6 mm (0.0630 in.)

      If the backlash is more than the maximum, replace the generator rotor and vacuum pump shaft.

  2. REMOVE VACUUM PUMP ASSEMBLY


    1. A0097QXE01
      Text in Illustration
      *a Matchmark

      Place matchmarks as shown in the illustration.

    2. Remove the 4 bolts and vacuum pump.

  3. REMOVE GENERATOR REAR END COVER


    1. A00983Z

      Remove the nut and terminal insulator.

    2. Remove the bolt, 3 nuts, rectifier plate and rear end cover.

  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. Remove the brush holder cover.

    2. A009C5B

      Remove the 2 screws and brush holder.

    3. Remove the plate seal.

  5. REMOVE GENERATOR REGULATOR ASSEMBLY


    1. A0098MI

      Remove the 3 screws and generator regulator.

  6. REMOVE GENERATOR HOLDER WITH RECTIFIER


    1. A0099NS

      Remove the 4 screws and generator holder with rectifier.

    2. Remove the 4 rubber insulators.

  7. REMOVE GENERATOR RECTIFIER END FRAME


    1. A009BMSE01
      Text in Illustration
      *1 Cord Clip

      Remove the 4 nuts and cord clip.

    2. A0099CSE01
      Text in Illustration
      *a Hold
      A009BSG Turn

      Using SST, remove the rectifier end frame.

      SST
      09286-46011

    3. Remove the washer from the rotor.

  8. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A0099JDE01

      Using SST and a press, press out the rotor.

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )