Disassembly

1GR-FE CHARGING: GENERATOR: DISASSEMBLY

1. REMOVE GENERATOR PULLEY CAP

(a) Using a screwdriver, remove the generator pulley cap.





2. REMOVE GENERATOR CLUTCH PULLEY

(a) Mount the generator in a vise between aluminum plates.

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





SST : 09820-63021

Text in Illustration





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

(c) Use a wrench to hold SST (A) and turn SST (B) counterclockwise to loosen the generator with clutch pulley.

NOTICE:
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.





Text in Illustration





(d) Remove SST from the generator.

(e) Remove the generator with clutch pulley from the rotor shaft.

3. REMOVE GENERATOR REAR END COVER

(a) Remove the nut and cord clamp.





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





4. REMOVE GENERATOR TERMINAL INSULATOR

(a) Remove the terminal insulator from the generator coil.





5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and brush holder from the generator coil.





6. REMOVE GENERATOR COIL ASSEMBLY

(a) Remove the 4 bolts.





(b) Using SST, remove the generator coil.





SST : 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04071

09957-04010

09958-04011

Text in Illustration





7. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the generator washer.





(b) Remove the generator rotor assembly.





8. REMOVE GENERATOR DRIVE END FRAME BEARING

(a) Remove the 4 screws and retainer plate from the drive end frame.





(b) Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.





SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07100