GENERATOR(for 80A Type) DISASSEMBLY

PROCEDURE


  1. REMOVE GENERATOR PULLEY CAP

    A005LTUE01
    Text in Illustration
    *1 Generator Pulley Cap

    1. Using a screwdriver, remove the generator pulley cap.

  2. REMOVE GENERATOR CLUTCH PULLEY

    A005HBYE04
    Text in Illustration
    *1 Rotor Shaft

    1. Clamp the generator housing stay in a vise tightly.

    2. Place the rotor shaft end into SST(A).

      SST
      09820-63021
    3. A005ILHE06
      Text in Illustration
      *1 Generator Clutch Pulley

      Fit SST(B) onto the generator clutch pulley.

    4. A005M7FE03
      Text in Illustration
      *a Hold
      *b Turn

      Loosen the generator clutch pulley by turning SST(B) in the direction as shown in the illustration.

      Note


      • Check that the generator housing stay is secured in a vise tightly.

      • Hold SST(A) tightly during the operation.

    5. Remove SST from the generator assembly.

    6. Remove the clutch pulley from the rotor shaft.

    7. Remove the generator assembly from a vise.

  3. REMOVE GENERATOR TERMINAL INSULATOR


    1. A005JN5

      Remove the nut and generator terminal insulator.

  4. REMOVE GENERATOR REAR END COVER


    1. A005GIU

      Place the generator assembly on the generator clutch pulley.

    2. A005GW3E02
      Text in Illustration
      *1 Rectifier Plate

      Remove the nut A, screw and rectifier plate.

    3. Remove the 2 nuts B and the generator rear end cover.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A005KT6E02
      Text in Illustration
      *1 Generator Brush Cover
      *2 Generator Brush Holder Assembly
      *3 Generator Plate Seal

      Remove the generator brush cover from the generator brush holder assembly.

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

    3. Remove the generator plate seal.

  6. REMOVE GENERATOR REGULATOR ASSEMBLY

    A005GLU

    1. Remove the 2 screws and generator regulator assembly.

  7. REMOVE GENERATOR HOLDER WITH RECTIFIER

    A005JW6

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

  8. REMOVE GENERATOR ROTOR ASSEMBLY

    A005HY9E01

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

      Text in Illustration
      *1 Terminal Insulator

    2. Remove the 4 nuts.

    3. A005JBYE01
      Text in Illustration
      *1 Wooden Block
      *a Hold
      *b Turn

      Using SST, remove the generator rectifier end frame.

      SST
      09286-46011
    4. A005IVV

      Remove the generator washer from the generator rotor assembly.

    5. A005J3DE03
      Text in Illustration
      *1 Wooden Block
      *2 Plastic Hammer

      Using a plastic hammer, remove the generator rotor assembly from the generator drive end frame assembly.

      Note

      Do not drop the generator rotor assembly.

      Tech Tips

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