Disassembly and Reassembly

DISASSEMBLY

1. 100 A:
REMOVE GENERATOR COVER (Canada) AND CORD CLIP
a. Canada:
Remove the bolt, nut, generator cover and cord clip.
b. Except Canada:
Remove the bolt and cord clip.




2. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.




b. Remove the 3 nuts and rear end cover.




c. Remove the 2 nuts, bolt, plate terminal and rear end cover.




3. 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.
c. Remove the seal plate from the rectifier end frame.




4. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.




5. 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. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
d. 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 than on-half of a turn.

e. Remove the generator from SST (C).
f. Turn SST (B), and remove SST (A and B).
g. Remove the pulley nut and pulley.




6. REMOVE RECTIFIER END FRAME
a. 80 A: Remove the 4 nuts and cord clip.
b. 100 A: Remove the 4 nuts.




c. Using SST, remove the rectifier end frame.
SST 09286-46011
d. Remove the generator washer.

7. REMOVE ROTOR FROM DRIVE END FRAME

REPLACEMENT




1. REPLACE FRONT BEARING
a. Remove the 4 screws and bearing retainer.




b. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00260, 09952-06010)




c. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00500)
d. Install the bearing retainer with the 4 screws.

Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)




2. REPLACE REAR BEARING
a. Using SST, remove the bearing cover (outside) and bearing.
SST 09820-00021

NOTE: Be careful not to damage the fan.

b. Remove the bearing cover (inside).




c. Place the bearing cover (inside) on the rotor.




d. Using SST and a press, press in a new bearing.
SST 09820-00030




e. Using SST, push in the bearing cover (outside).
SST 09285-76010

REASSEMBLY




1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME




3. INSTALL RECTIFIER END FRAME
a. Place the generator washer on the rotor.




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




c. 80 A:
Install the cord clip and 4 nuts.

Torque:
A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
B: 5.4 N.m (55 kgf.cm, 48 in.lbf)

d. 100 A:
Install the 4 nuts.

Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)




4. 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. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
e. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.

Torque: 110.5 N.m (1,128 kgf.cm, 81 ft.lbf)

f. Remove the generator from SST (C).
g. Turn SST (B), and remove SST (A and B).




5. INSTALL RECTIFIER HOLDER
a. Install the 4 rubber insulators on the lead wires.




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

Torque: 2.94 N.m (30 kgf.cm, 26 in. lbf)




6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Place the seal plate on the rectifier end frame.




b. Place the voltage regulator and brush holder on the rectifier end frame.

NOTE: Be careful of the holder installation direction.

c. Install the 5 screws.

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




d. Place the brush holder cover on the brush holder.




7. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the 2 nuts and bolt.

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




b. Install the rear end cover with the 3 nuts.

Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)




c. Install the terminal insulator with the nut.

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

8. 100 A:
INSTALL GENERATOR COVER (Canada) AND CORD CLIP
a. Canada:
Install the cord clip and generator cover with the bolt and nut.

Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf)

b. Except Canada:
Install the cord clip with the bolt.

Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf)

9. CHECK THAT ROTOR ROTATES SMOOTHLY