Overhaul

Generator:

DISASSEMBLY

1. REMOVE GENERATOR PULLEY WITH CLUTCH

a. Remove the cap from the pulley.

1. Using a screwdriver, puncture the center of the cap and pry it off.

NOTE: Do not reuse the cap.

b. Install SST to the pulley and vise as shown in the illustration.

SST 09820-63020

c. Mount SST (A) in a vise.

d. Turn SST (B)clockwise to loosen the pulley.
e. Remove the pulley.

2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

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

b. Remove the terminal insulator.

c. Remove the 2 screws and generator brush holder.

3. REMOVE GENERATOR ROTOR ASSEMBLY

a. Remove the bolt and cord clip.

b. Remove the 4 bolts.

c. Using SST, remove the coil.

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

d. Remove the washer.
e. Remove the generator rotor.

REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

a. Install the washer onto the generator rectifier end frame.

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

c. Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame.

d. Tighten the 4 bolts.

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

e. Install the cord clip with the bolt.

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

2. 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.

d. Install the terminal insulator onto the generator rectifier end frame.

e. Install the generator rear end cover with the 3 nuts.

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

3. INSTALL GENERATOR PULLEY WITH CLUTCH
a. Install the pulley by hand.

b. Install SST to the pulley and vise as shown in the illustration.

SST 09820-63020

c. Turn SST (B) counterclockwise to tighten the pulley.

Torque: 110 N.m (1122 kgf.cm, 82 ft.lbf)

d. Install a new cap to the pulley.
e. Check that the generator pulley rotates smoothly.