Overhaul
DISASSEMBLY1. REMOVE CLUTCH PULLEY
a. Using a screwdriver, remove 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 REAR END COVER
a. Place the generator assembly on the clutch pulley.
b. Remove the 3 nuts and end cover.
3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator from the generator coil.
4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the 2 screws and brush holder from the generator coil.
5. REMOVE GENERATOR COIL ASSEMBLY
a. Remove the 4 bolts.
b. Using SST, remove the generator coil assembly.
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 generator washer.
b. Remove the rotor assembly from the drive end frame.
7. INSPECT GENERATOR DRIVE END FRAME BEARING
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), 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 (09951-00470), 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 rotor assembly to the drive 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. Install the generator coil assembly with the 4 bolts.
Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes into the generator brush holder assembly, insert a Dia 1.0 mm (0.039 in.) pin into the brush holder hole.
b. Install the generator brush holder assembly to the generator coil with the 2 screws.
Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
c. Pull out the pin from the generator brush holder.
5. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator to the generator coil.
6. INSTALL GENERATOR REAR END COVER
a. Install the generator rear end cover to the generator coil with the 3 nuts.
Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
7. INSTALL 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 (1,127 kgf.cm, 81 ft.lbf)
NOTE: The torque should be used for tightening without using 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 the new clutch pulley cap to the clutch pulley.