GENERATOR DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A010KSX

      Using a screwdriver, puncture the center of the generator pulley cap and pry it off.

      Note

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR WITH CLUTCH PULLEY


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

    2. A010JLUE01
      Text in Illustration
      *1 Rotor Shaft

      Install SST A and 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 rotor shaft.

    3. A010LL0E01
      Text in Illustration
      *a Hold
      A010JYS Turn

      Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator with clutch pulley.

      Note

      Be careful as the generator with clutch pulley or 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. A010H49

      Place the generator on the generator with clutch pulley.

    2. A010LOO

      Remove the 3 bolts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR


    1. Remove the terminal insulator from the generator coil.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A010JO6

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A010I1J

      Remove the 4 bolts.

    2. A010HC1E15
      Text in Illustration
      *a Hold
      A010JYS 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. A010L43

      Remove the washer.

    2. A010M1Q

      Remove the generator rotor.

  8. INSPECT GENERATOR ROTOR BEARING


    1. A010GUB

      Check that the bearing is not rough or worn and that it rotates smoothly.

      If necessary, replace the generator rotor bearing.

  9. REMOVE GENERATOR ROTOR BEARING


    1. A010GUV

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

    2. A010KDHE01

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

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