Disassembly and Reassembly

DISASSEMBLY




1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.




b. Remove the screw, 3 nuts, plate terminal and end cover.




2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the brush holder cover from the brush holder.
b. Remove the 5 screws, brush holder and voltage regulator.




3. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
c. Remove the seal plate.




4. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
b. Check that SST (A) is secured to the rotor shaft.




c. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
d. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.

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

e. Remove the generator from SST (C).
f. Turn SST (B) and remove SST (A and B).
g. Remove the pulley nut and pulley.




5. REMOVE RECTIFIER END FRAME
a. Remove the 4 nuts and wire clamp.




b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer.

6. REMOVE ROTOR FROM DRIVE END FRAME

REASSEMBLY




1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO RECTIFIER END FRAME




3. INSTALL RECTIFIER END FRAME
a. Place the generator washer on the rotor.




b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.




c. Install the 3 nuts.
Torque: 4.5 Nm (46 kg.cm, 40 in.lb)
d. Install the wire clip with the nut.
Torque: 5.4 Nm (55 kg.cm, 48 in.lb)




4. 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 09820-63010
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
c. Check that SST (A) is secured to the pulley shaft.




d. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
e. To torque the pulley nut turn SST (A) in the direction shown in the illustration.
Torque: 110.5 Nm (1,125 kg.cm, 81 ft.lb)
f. Remove the generator from SST (C).
g. Turn SST (B) and remove SST (A and B).




5. INSTALL RECTIFIER HOLDER
a. Place the seal plate on the rectifier end frame.




b. Install the 4 rubber insulators on the lead wires.




c. Install the rectifier holder with the 4 screws.
Torque: 2.9 Nm (30 kg.cm, 26 in.lb)




6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Place the voltage regulator together and brush holder on the rectifier end frame.

NOTE: Be careful of the holder installation direction.

b. Install the 5 mounting screws.
Torque: 2.0 Nm (20 kg.cm, 18 in.lb)




c. Place the brush holder cover on the brush holder.




7. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the 3 nuts and screw.

Torque: Nut: 4.4 Nm (45 kg.cm, 39 in.lb)
Screw: 3.9 Nm (39 kg.cm, 35 in.lb)

b. Install the terminal insulator with the nut.
Torque: 6.5 Nm (67 kg.cm, 58 in.lb)

8. CHECK THAT ROTOR ROTATES SMOOTHLY