Disassembly and Reassembly

DISASSEMBLY

1. REMOVE REAR END COVER
(a) Remove the 3 nuts and end cover.
(b) Remove the terminal insulator.

2. REMOVE BRUSH HOLDER
Remove the 2 screws and brush holder.

3. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
(b) Check that SST (A) is secured to the rotor shaft.

(e) Loosen the pulley nut by turning SST (A) in the direction shown in the illustration.

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

(f) Remove the generator from SST (C).

(g) Turn SST (B) and remove SST (A and B).
(h) Remove the pulley nut and pulley.

4. REMOVE RECTIFIER END FRAME

(a) Remove the 4 bolts.

(b) Using SST, remove the end frame.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011)

5. REMOVE GENERATOR ROTOR
Remove the generator washer and rotor.

INSPECTION
1. INSPECT GENERATOR ROTOR

(a) Check if the rotor has an open circuit.
(1) Using an ohmmeter, measure the resistance between the slip rings.
Standard: 2.3 to 2.7 Ohms at 20°C (68°F)
If the resistance is not as specified, replace the rotor.

(b) Check if the rotor is grounded.
Using an ohmmeter, check the resistance between the slip ring and the rotor core.
Standard: 10 kOhm or higher
If the resistance is not as specified, replace the rotor.

(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.

(d) Using a vernier caliper, measure the slip ring diameter.
Specified diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
If the diameter is less than the minimum, replace the rotor.

2. INSPECT BRUSH HOLDER
Using a vernier caliper, measure the exposed brush length.
Standard exposed brush length: 10.5 mm (0.413 in.)
Minimum exposed brush length: 4.5 mm (0.177 in.)
If the exposed brush length is less than the minimum, replace the holder.

3. INSPECT BEARING
Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.

REPLACEMENT
1. REPLACE FRONT BEARING

(a) Remove the 4 screws, bearing retainer and bearing.

(b) Using SST and a hammer, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)

(c) Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)

(d) Install the bearing retainer with the 4 screws.
Torque: 2.3 Nm (23 kgf-cm, 20 in.-lbf)

REASSEMBLY

1. INSTALL GENERATOR ROTOR
(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.
(c) Install the generator washer.

2. INSTALL RECTIFIER END FRAME

(a) Using a 21 mm deep socket wrench and press, carefully press in the rectifier end frame.

(b) Tighten the 4 bolts.
Torque: 5.8 Nm (59 kgf~cm, 51 in.~lbf)

3. INSTALL PULLEY

(a) Install the pulley to the rotor shaft by tightening the pulley nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
(c) Check that SST (A) is secured to the pulley shaft.

(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C) to attach the pulley nut to SST (C).

(f) Tighten the pulley nut by turning SST (A) in the direction shown in the illustration.
Torque: 110.3 Nm (1,125 kgf-cm, 81 ft-lbf)
(g) Remove the generator from SST (C).

(h) Turn SST (B) and remove SST (A and B).

(i) Place the brush holder on the rectifier end frame with the pin facing upward.
(j) Install the 2 screws.
Torque: 1.8 Nm (18 kgf-cm, 16 in.-lbf)

4. INSTALL REAR END COVER

(a) Install the terminal insulator.

NOTICE: Be careful of the insulator's installation direction.

(b) Install the end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgf-cm, 41 in.-lbf)

5. CHECK ROTOR ROTATES ROTATION
Check that the rotor rotates smoothly.