Disassembly and Assembly

DISASSEMBLY

1. Remove the generator (GEN) from the vehicle.
2. Remove the four housing bolts.
3. On this generator, remove the two rear shield screws and remove the rear shield covering the diode plate insulator.







4. Use a flat-blade screwdriver to separate the generator front housing and stator and coil.







5. Remove the generator front housing and generator rotor from the stator and coil.







6. Place the generator rotor in a vise equipped with soft jaws. Clamp the vise around the outside of the generator rotor. Remove the generator pulley nut and generator pulley washer.
7. Remove the generator pulley, inner and outer front seal, and spacer.
8. Separate the generator rotor and generator front housing.







9. Remove the front bearing plate screws and remove the front bearing plate.
10. Use a suitable driver to fit the generator front bearing outer race and remove the generator front bearing. Use a press or vise to press the generator front bearing from the generator front housing.







11. On this generator, remove the rear shield and the diode plate insulator from the generator rear housing and bearing.







12. Remove the rectifier screw and the two voltage regulator screws that secure the voltage regulator (VR) and rectifier to the generator rear housing and bearing.







13. Remove the stator and coil, with the voltage regulator and rectifier attached, from the generator rear housing and bearing.







14. Unsolder the stator and coil from the rectifier.

CAUTION: Work quickly, applying the soldering iron for no more than 5 seconds to avoid heating and possible damage to the diodes.







15. Unsolder the voltage regulator from the rectifier.
16. Remove the stopper ring from the generator rear bearing.







17. Use a suitable press and Bearing Pulling Attachment D84L-1122-A or equivalent to remove the generator rear bearing from the generator rotor.

ASSEMBLY

1. Use a suitable driver on the generator rear bearing inner race to press the generator rear bearing onto the generator rotor shaft until it contacts the generator rotor shaft step.

NOTE: Install the generator rear bearing with the stopper ring groove to the slip ring side.







2. Fit the stopper ring into the eccentric groove in the generator rear bearing circumference. The protruding part of the stopper ring should fit into the deepest part of the eccentric groove. Note that, for easy recognition, the edge of the deepest part of the eccentric groove is chamfered. By fitting the stopper ring in this way, the amount of stopper ring protruding from the eccentric groove is lessened, making assembly easier.







3. Reassemble the rectifier, voltage regulator and stator and coil by soldering the leads in the reverse order of disassembly.

Use only rosin core solder. Hold the stator and coil leads with a pair of needlenose pliers when soldering. The pliers act as a heat sink, and will protect the diodes. Do not solder for more than 5 seconds.

CAUTION: Work quickly, applying the soldering iron for no more than 5 seconds to avoid damage to the diodes.

4. Position the stator and coil, with rectifier and voltage regulator attached, on the generator rear housing and bearing.







5. Install the stator and coil in the generator rear housing and bearing by evenly pressing the stator and coil into the generator rear housing and bearing.







6. Install the rectifier screw and the two voltage regulator screws.







7. Depress the generator brushes. Use a stiff wire (a straightened paper clip will work) to retain the generator brushes in the voltage regulator while assembling the generator.
8. On this generator, replace the diode plate insulator, the rear shield and two rear shield screws on the generator rear housing and bearing.
9. Press the generator front bearing into the generator front housing using a press or a vise and a suitable driver to fit the generator front bearing outer race.
10. Install the front bearing plate. Tighten the front bearing plate screws to 2.0-5.3 N.m (18-47 lb-in).
11. Position the generator rotor in a vise with soft jaws. Clamp around the outside of the generator rotor.
12. Install the generator front housing, inner and outer front seal, spacer, generator pulley, generator pulley washer, and generator pulley nut onto the generator rotor.
13. Tighten the generator pulley nut to 59-98 N.m (44-72 lb-ft).
14. Heat the generator rear housing and bearing around the generator rear bearing seat with a 200 W soldering iron. Heat the generator rear housing and bearing to no more than 50-60°C (122-140°F).
15. Position the generator front housing and generator rotor to the stator and coil.
16. Install the four housing bolts. Tighten the housing bolts alternately and evenly to draw the halves together uniformly. Tighten the housing bolts to 3.0-6.3 N.m (27-56 lb-in).
17. Remove the wire used to hold the generator brushes.
18. Rotate the generator pulley manually. There should be no drag and the generator rotor should turn easily 360 degrees. If the generator rotor does not spin easily, disassemble the generator to determine the cause.
19. Install the generator in the vehicle.