Disassembly and Reassembly

DISASSEMBLY




1. REMOVE GENERATOR CLUTCH PULLEY
a. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.

NOTE: Do not reuse the generator pulley cap.




b. Set SST (A) and (B).

SST 09820-63020

c. Clamp SST (A) in a vise.




d. Place the rotor shaft end into SST (A).




e. Fit SST (B) to the clutch pulley.




f. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
g. Remove the generator assembly from the SST
h. Remove the clutch pulley from the rotor shaft.




2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Place the generator assembly on the clutch pulley.




b. Remove the 3 nuts and generator rear end cover.




3. REMOVE GENERATOR TERMINAL INSULATOR
a. Remove the terminal insulator.




4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the 2 screws and generator brush holder.




5. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the 4 bolts.




b. Remove the bolt and cord clip.




c. Using SST, remove the coil.

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




6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the washer.




b. Remove the generator rotor.




7. REMOVE GENERATOR DRIVE END FRAME BEARING
a. Remove the 4 screws and bearing retainer.




b. Using SST and a hammer, tap out the bearing.

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

REASSEMBLY




1. INSTALL GENERATOR DRIVE END FRAME BEARING
a. Using SST and a press, press in a new generator drive end frame bearing.

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




b. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
c. Install the 4 screws.

Torque: 2.3 N.m (23 kgf.cm, 20 in.lbf)

2. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the drive end frame on the clutch pulley.




b. Install the generator rotor onto the generator rectifier end frame.




c. Place a new generator washer on the generator rotor.




3. INSTALL GENERATOR COIL ASSEMBLY
a. Using SST and a press, press in the generator coil assembly to the drive end frame.

SST 09612-70100 (09612-07240)




b. Tighten the 4 bolts.

Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)




c. Install the cord clip with the bolt.

Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)




4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.




b. Install the generator brush holder with the 2 screws.

Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)




c. Pull the pin out of the generator brush holder.




5. INSTALL GENERATOR TERMINAL INSULATOR
a. Install the terminal insulator onto the generator rectifier end frame.




6. INSTALL GENERATOR REAR END COVER
a. Install the generator rear end cover with the 3 nuts.

Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)

7. INSTALL GENERATOR CLUTCH PULLEY
a. Temporarily install the clutch pulley onto the rotor shaft.




b. Set SST (A) and (B).

SST 09820-63020

c. Clamp SST (A) in a vise.




d. Place the rotor shaft end into SST (A).




e. Fit SST (B) to the clutch pulley.




f. Tighten the pulley by turning SST (B) in the direction shown in the illustration.

Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf)

NOTE: The torque shown should be used for tightening without using the SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST.

g. Remove the generator assembly from the SST.
h. Check that the clutch pulley rotates smoothly
i. Install a new clutch pulley cap to the clutch pulley.