GENERATOR DISASSEMBLY


  1. REMOVE GENERATOR WITH CLUTCH PULLEY (w/ Clutch Pulley)


    1. B007RF3E01

      Using a screwdriver, remove the generator pulley cap from the generator with clutch pulley.

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

    3. B007TCTE03

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

      SST
      09820-63020

      Note

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

    4. B007T3HE03

      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.

    5. Remove SST from the generator.

    6. Remove the generator with clutch pulley from the rotor shaft.

  2. REMOVE GENERATOR PULLEY (w/o Clutch Pulley)


    1. Install SST (1-A) to the pulley shaft.

      SST
      09820-63010   ( 09820-06010, 09820-06020 )
      HINT:
      SST (1-A) and (1-B) 09820-06010
      SST 2 09820-06020

    2. Install SST (1-B) to SST (1-A).

    3. B007ORUE01

      Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise with the specified torque.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is secured to the generator rotor shaft.

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

    5. B007Q21E01

      Insert SST 2 and attach it to the pulley nut.

    6. B007VONE01

      To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration.

      Note

      To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn.

    7. Remove SST 2 from the generator.

    8. B007PP6E01

      Turn SST (1-A), and remove SST (1-A) and (1-B).

    9. Remove the generator pulley nut and generator pulley.

  3. REMOVE GENERATOR REAR END COVER


    1. B007VJC

      Remove the 3 nuts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR


    1. B007S79

      Remove the terminal insulator.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. B007QLO

      Remove the 2 screws and generator brush holder assembly.

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. B007T3X

      Remove the 4 through bolts.

    2. B007T6XE01

      Using SST, remove the generator coil assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )

  7. REMOVE GENERATOR ROTOR ASSEMBLY


    1. Remove the generator washer.

    2. Remove the generator rotor assembly from the generator rear end cover.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. B007PLT

      Check that the generator drive end frame bearing is not rough or worn.

      If necessary, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. B007THX

      Remove the 4 screws and bearing retainer.

    2. B007QGRE01

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

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