GENERATOR DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A00DTJG

      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. A00DQ9AE01

      Mount the generator in a vise between aluminum plates.

    2. Install SST (A) and (B) to the pulley as shown in the illustration.

      Text in Illustration
      *1 Rotor Shaft
      SST
      09820-63021

      Note

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    3. A00DQPHE01

      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. A00DQJS

      Place the generator on the generator with clutch pulley.

    2. A00DQQK

      Remove the 3 nuts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR


    1. A00DTES

      Remove the terminal insulator from the generator coil.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A00DQ6E

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A00DR8N

      Remove the 4 bolts.

    2. A00DURVE04
      Text in Illustration
      *1 Hold
      *2 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. A00DTOM

      Remove the washer.

    2. A00DTSJ

      Remove the generator rotor.

  8. REMOVE GENERATOR ROTOR BEARING


    1. A00DV06

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

    2. A00DS8ME01

      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 )