Disassembly and Reassembly

Generator / Exploded View:

GENERATOR 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 N.m (400 kgf.cm, 29 ft.lbf)

b. Check that SST (A) is secured to the rotor shaft.







c. Mount SST (C) in a vise.
d. Install the generator to SST (C).
e. 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 then one-halt of a turn.

f. Remove the generator from SST (C).







g. Turn SST (B) and remove SST (A and B).
h. Remove the pulley nut and pulley.

5. REMOVE RECTIFIER END FRAME
Remove the 4 nuts and 2 wire clips.







a. Using SST, remove the rectifier end frame.
SST 09950-40010

b. Remove the thrust washer.

6. REMOVE ROTOR FROM DRIVE END FRAME


GENERATOR ASSEMBLY

1. INSTALL ROTOR TO DRIVE END FRAME
a. Place the rectifier end frame on the pulley.
b. Install the rotor to the rectifier end frame.

2. INSTALL RECTIFIER END FRAME







a. Place the thrust washer on the rotor.







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







c. Install the 2 wire clips with the nuts.

Torque:
Nut:
4.5 N.m (46 kgf.cm, 40 in.lbf)
Wire clip with nut:
5.4 N.m (55 kgf.cm, 48 in.lbf)

3. 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 N.m (400 kgf.cm, 29 ft.lbf)

c. Check that SST (A) is secured to the pulley shaft.






d. Mount SST (C) in a vise.
e. Install the generator to SST (C).
f. To torque the pulley nut turn SST (A) in the direction shown in the illustration.

Torque: 110.5 N.m (1,128 kgf.cm, SI ft.lbf)

g. Remove the generator from SST (C).







h. Turn SST (B), and remove SST (A and B).

4. INSTALL RECTIFIER HOLDER







a. Place the seal plate on the rectifier end frame.
b. Install the 4 rubber insulators on the lead wires.

NOTE: Be careful of rubber Insulators installation direction.







c. Install the rectifier holder while pushing it with the 4 screws.

Torque: 2.9 N.m (30 kgf.cm, 25 in.lbf)







5. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame.
b. Install the 5 screws.
c. Place the brush holder cover on the brush holder.

Torque: 2.0 N.m (20 kgf.cm. 17 in.lbf)







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

Torque:
Screw: 3.8 N.m (39 kgf.cm. 34 in.lbf)
Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)

b. Install the terminal insulator with the nut.

Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)

7. CHECK THAT ROTOR ROTATES SMOOTHLY