Disassembly and Assembly

DISASSEMBLY






1. Remove the four generator housing bolts.







2. Tap the generator rear housing evenly with a soft-faced hammer to separate the generator rear housing and stator and coil from the generator front housing and generator rotor assembly.







3. Use Bearing Pulling Attachment D84L-1122-A, or equivalent, and Crankshaft Damper Remover T74P-6316-A to remove the generator rear bearing from the generator rotor shaft. Remove the stopper ring from the generator rear bearing.







4. Place the generator rotor in a vise equipped with soft jaws. Clamp the vise around the outside of the generator rotor. Remove the generator pulley nut and lockwasher.
5. Remove the generator pulley.
6. Separate the generator rotor from the generator front housing.







7. Remove the four bearing plate screws and remove the bearing plate.







8. Using a socket or driver that fits the generator front bearing outer race and a press, remove the generator front bearing from the generator front housing.
9. Remove the B-terminal nut and insulator from the B-terminal.







10. Remove the rectifier screw and the three voltage regulator screws.







11. Remove the stator and coil, with the voltage regulator and the rectifier attached, from the generator rear housing.







12. If the generator rear bearing is still in the generator rear housing, use an appropriate Collect (part of D80L-100-A) or equivalent and Hammer D80L-100-D to remove the generator rear bearing from the generator rear housing.
13. Remove the two plastic shields from the voltage regulator and brush holder.
14. Unsolder the stator and coil from the voltage regulator.

CAUTION: Apply the soldering iron for no more than 5 seconds to avoid overheating the rectifier and possibly damaging the diodes.







15. Unsolder the rectifier from the voltage regulator.

ASSEMBLY







1. Reassemble the rectifier, the voltage regulator, and the stator and coil by soldering the leads in the reverse order of disassembly.

CAUTION: Hold the stator leads with a pair of needlenose pliers when soldering. The pliers act as a heat sink and will protect the diodes. Do not solder for more than 5 seconds. Use only rosin core solder.

2. Install the two plastic shields to the voltage regulator in the reverse order of disassembly.
3. Install the stator and coil, with the voltage regulator and the rectifier attached, to the generator rear housing.







4. Install the rectifier screw and the three voltage regulator screws to the generator rear housing. Tighten the rectifier screw to 2-5 N.m (18-44 Lb-in). Tighten the voltage regulator screws to 2-5 N.m (18-44 Lb-in).
5. Install the insulator and nut on the B-terminal.







6. Depress the brush springs and brushes. Use a stiff wire (a straightened paper clip will work) to retain the brushes in the voltage regulator while assembling the generator.







7. Press the generator front bearing into the generator front housing using a press or a vise and a suitable driver to fit the generator front bearing outer race.
8. Install the bearing plate and the four bearing plate screws. Tighten the four bearing plate screws to 2-5 N.m (18-44 Lb-in).
9. Position the generator rotor in a vise with soft jaws. Clamp the vise around the outside of the generator rotor.
10. Install the generator front housing onto the generator rotor.
11. Install the generator pulley, the lockwasher, and the generator pulley nut onto the generator rotor.
12. Tighten the generator pulley nut to 83-108 N.m (61-80 Lb-Ft.).
13. If the generator rear bearing was removed during disassembly. position the generator rear bearing on the end of the generator rotor shaft.
14. Place a socket or driver on the generator rear bearing inner race and tap the generator rear bearing onto the generator rotor shaft up to the step in the generator rotor shaft.







15. Fit the stopper ring into the eccentric groove of the generator rear bearing circumference. The protruding part of the stopper ring should fit into the deepest part of the eccentric groove. Note that for easy recognition, the edge of the deepest part of the eccentric groove is chamfered. By fitting the stopper ring in this way, the amount of stopper ring protruding from the eccentric groove is lessened, making assembly easier.
16. Install the generator front housing and generator rotor assembly to the generator rear housing and stator and coil assembly.
17. Install the four generator housing bolts. Tighten the generator housing bolts to 4-5 N.m (36-44 Lb-in).

NOTE: Tighten generator housing bolts alternately to draw the generator front housing and generator rear housing together evenly.

18. Remove the wire used to hold the brushes.
19. Rotate the generator pulley manually. The generator pulley should spin easily. If the generator rotor does not turn easily, disassemble the generator to determine the cause.