GENERATOR (for 80A Type) DISASSEMBLY


  1. REMOVE GENERATOR PULLEY


    1. Clamp the generator housing stay in a vise.

    2. A0117PME01
      Text in Illustration
      *a Hold
      *b Turn

      Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )
      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

      Tech Tips

      SST 1-A and B 09820 - 06010
      SST 2 09820 - 06021
    3. A0118LSE01
      Text in Illustration
      *a Insert

      Insert SST 2, and attach the pulley nut to SST 2.

    4. A011BCUE01
      Text in Illustration
      *a Hold
      *b Turn

      To loosen the generator pulley nut, turn SST 1-A in the direction shown in the illustration.

      Note

      To prevent damage to the rotor shaft, do not loosen the generator pulley nut by more than one half turn.

    5. Remove SST 2 from the generator.

    6. A0118Z7E01
      Text in Illustration
      *a Hold
      *b Turn

      Turn SST 1-B, and remove SST 1-A and B.

    7. Remove the generator pulley nut and generator pulley.

  2. REMOVE GENERATOR TERMINAL INSULATOR


    1. A01171S

      Remove the nut and generator terminal insulator.

  3. REMOVE GENERATOR REAR END COVER


    1. A01181E

      Remove the nut, bolt and rectifier plate.

    2. Remove the 2 nuts and rear end cover.

  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0119BJ

      Remove the brush cover from the generator brush holder assembly.

    2. Remove the 3 screws and generator brush holder assembly.

    3. Remove the plate seal.

  5. REMOVE GENERATOR REGULATOR ASSEMBLY

    A0118CP

    1. Remove the 2 screws and generator regulator assembly.

  6. REMOVE GENERATOR HOLDER WITH RECTIFIER

    A011BK3

    1. Remove the 3 screws and generator holder with rectifier.

  7. REMOVE GENERATOR ROTOR ASSEMBLY

    A0119O6E01
    Text in Illustration
    *1 Terminal Insulator

    1. Remove the 3 terminal insulators from the rectifier end frame.

    2. Remove the 4 nuts.

    3. A01179WE01
      Text in Illustration
      *1 Wooden Block
      *a Turn
      *b Hold

      Using SST, remove the rectifier end frame.

      SST
      09286-46011

    4. Remove the generator washer.

    5. A01188VE01
      Text in Illustration
      *1 Wooden Block

      Remove the generator rotor assembly from the drive end frame.

      Note

      Do not drop the generator rotor assembly.

      Tech Tips

      If the generator rotor is engaged too firmly, gently tap the generator rotor shaft to remove it using a plastic hammer.