Disassembly and Reassembly

DISASSEMBLY




1. For easier reinstallation, provide match marks on both front and rear housing as shown before separating them.




2. Remove housing bolts from generator.




3. Then with lever inserted between stator core and front housing, separate generator into front and rear sides.




4. Loosen pulley nut by using vise and take off pulley.

NOTE: When using vise, put clean cloth between rotor and vise so as not to cause damage to rotor.




5. Remove rotor from front housing.
6. When removing front bearing, remove bearing retainer screws and retainer.




7. When removing rear bearing, use oil hydraulic press.




8. Remove stator from rear housing by removing four screws and battery terminal nut.




9. To remove brush, remove wire cover from brush holder and then disconnect brush wire from regulator terminal by using soldering iron.

REASSEMBLY




Reassemble in reverse order of DISASSEMBLY, noting the following.
1. Be sure to check for proper installing direction of brush.
Also, when soldering brush wire, make sure to position brush as shown in figure.




2. Tighten generator pulley nut to specified torque.

Tightening Torque
Pulley nut: 67.5 N.m (6.75 kg-m, 49.0 lb-ft)

3. Push brushes into brush holder, then support brushes by inserting appropriate wire from hole of rear housing.
Then with bearing box of rear housing heated up to 50 ° to 60 °C (122 ° to 140 °F), install rotor to rear housing.

NOTE:
- After installing rotor, remove wire and install hole plug to rear housing.
- Check to make sure that match marks on front and rear housing are aligned.

4. After assembling generator, make sure that rotor turns smoothly.