GENERATOR (for 100 A Type) DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A01ITJP

      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 PULLEY WITH CLUTCH


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

    2. A01IPF3E01
      Text in Illustration
      *1 Rotor Shaft

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

      SST
      09820-63021

      Note

      Securely install SST to the generator pulley and generator rotor shaft.

    3. A01IQO1E02
      Text in Illustration
      *a Hold
      A01ISM9 Turn

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

      Note

      Be careful as the generator 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 pulley from the rotor shaft.

  3. REMOVE GENERATOR REAR END COVER


    1. A01IRL1

      Place the generator on the generator pulley.

    2. Remove the 3 bolts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR


    1. A01IN0S

      Remove the terminal insulator from the generator coil.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01IU7Q

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A01INRZ

      Remove the 4 bolts from the drive end frame.

    2. A01IP5AE04
      Text in Illustration
      *a Hold
      A01ISM9 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. A01ITHNE01
      Text in Illustration
      *1 Washer
      *2 Generator Rotor

      Remove the washer and generator rotor.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A01IOKR

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

      If the bearing does not rotate smoothly, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A01ISB9

      Remove the 4 screws and retainer plate.

    2. A01IO6SE01

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

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