Generator Disassembly and Reassembly
Generator Disassembly and Reassembly
Generator Removal and Installation
Generator Components
Disassembly
1) For easier reinstallation, provide match marks (3) on drive end frame (1) and rear end frame (2) as shown.
2) Remove end frame bolts (1) from generator.
3) With lever (1) inserted between stator core (2) and drive end frame (3), separate generator into drive end frame (3) and rear side.
4) Remove pulley as follows.
- M/T model
a Hold rotor (2) using vise (4) via clean cloth (3).
NOTE:
The rotor may be damaged if it is not held in a vise in the specified method and at the indicated parts when loosening the pulley nut.
Be sure to hold the rotor in the vise via a clean cloth at the iron parts (5). Never hold the rotor at other parts (6).
b Loosen pulley nut and remove pulley (1).
- CVT model
a Hold rotor (2) using vise (4) via clean cloth (3).
NOTE:
The rotor may be damaged if it is not held in a vise in the specified method and at the indicated parts when loosening the pulley nut.
Be sure to hold the rotor in the vise via a clean cloth at the iron parts (5). Never hold the rotor at other parts (6).
b Remove pulley (1) using special tool.
Special Tool
(A): 09932-96510
5) Remove drive end frame from rotor.
6) Remove bearing retainer screws (1) and bearing retainer.
7) Remove drive end bearing from drive end frame (1) using special tool and hydraulic press (2).
Special Tool
(A): 09943-88211
8) Remove rear end bearing (1) using hydraulic press (2), general rod (3) and general tool (4).
9) Remove three screws (1) and generator "B" terminal nut (2).
10) Remove stator with IC regulator assembly and rectifier assembly from rear end frame.
11) Unsolder stator leads (1) and remove stator (2) from rectifier assembly.
12) To remove brush, remove holder (1) from brush holder (2) and then disconnect brush wire (3) from regulator terminal using soldering iron.
Reassembly
Generator Disassembly and Reassembly
Reverse disassembly procedure for reassembly noting the following.
- Tighten each bolt, nut, screw and pulley (CVT model) to specified torque referring to Generator Components Generator Components.
- Be sure to install brushes (1) in the proper direction as shown and solder brush wires (2) and stator leads (3).
- Install drive end bearing to drive end frame (1) using special tool and hydraulic press (2).
Special Tool
(A): 09913-76010
- Push brushes into brush holder, then support brushes by inserting appropriate wire (1) before installing IC regulator assembly (2) to rear end frame (3).
NOTE:
After installing rotor, remove wire.
- Install rear end bearing (3) as the following steps.
a Degrease inner of bearing box part (1) of rear end frame (2) and outer of rear end bearing.
b Heat bearing box part of rear end frame to a temperature of 50 - 60 °C (122 - 144 °F).
c Install rear end bearing with rotor into bearing box part of rear end frame.
NOTE:
If the rear end bearing is press-fitted into the bearing box that is not heated, the bearing could be damaged.
Be sure to heat the bearing box to the specified temperature before press-fitting the rear end bearing.
NOTE:
Check that match marks on front and rear end frame are aligned.
- After assembling generator, make sure that rotor turns smoothly.