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GENERATOR DISASSEMBLY

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  1. Click here

    REMOVE GENERATOR PULLEY CAP


    1. A01IN8G

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

      Note:

      Do not reuse the generator pulley cap.

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    REMOVE GENERATOR PULLEY WITH CLUTCH


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

    2. A01IR6QE01

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

      09820-63021
      Table 1. Text in Illustration
      *1 Rotor Shaft
      Note:

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

    3. A01IR9RE01

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

      Table 2. Text in Illustration
      *a Hold
      A01ISM9 Turn
      Note:

      Be careful as the generator pulley with clutch 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 pulley with clutch from the rotor shaft.

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    REMOVE GENERATOR REAR END COVER


    1. A01IQAH

      Place the generator on the generator pulley with clutch.

    2. A01IOJS

      Remove the 3 bolts and generator rear end cover.

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    REMOVE TERMINAL INSULATOR


    1. Remove the terminal insulator from the generator coil.

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    REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01IOB5

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

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    REMOVE GENERATOR COIL ASSEMBLY


    1. A01IQMI

      Remove the 4 bolts.

    2. A01IUPDE15

      Using SST, remove the generator coil.

      09950-40011 09951-04020 09952-04010 09953-04020 09954-04010 09955-04071 09957-04010 09958-04011
      Table 3. Text in Illustration
      *a Hold
      A01ISM9 Turn
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    REMOVE GENERATOR ROTOR ASSEMBLY


    1. A01IRYM

      Remove the washer.

    2. A01IU31

      Remove the generator rotor.

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    INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A01IP5G

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

      If necessary, replace the generator drive end frame bearing.

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    REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A01ITU3

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

    2. A01IR8RE01

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

      09950-60010 09951-00250
      09950-70010 09951-07100