GENERATOR DISASSEMBLY


  1. 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.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH


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

    2. A01IR6QE01
      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 attach SST to the generator pulley with clutch and rotor shaft.

    3. A01IR9RE01
      Text in Illustration
      *a Hold
      A01ISM9 Turn

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

      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.

  3. 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.

  4. REMOVE TERMINAL INSULATOR


    1. Remove the terminal insulator from the generator coil.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01IOB5

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A01IQMI

      Remove the 4 bolts.

    2. A01IUPDE15
      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. A01IRYM

      Remove the washer.

    2. A01IU31

      Remove the generator rotor.

  8. 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.

  9. 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.

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