Overhaul

DISASSEMBLY




1. REMOVE GENERATOR PULLEY

SST 09820-63010 (09820-06010, 09820-06020)




a. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




b. Mount SST 2. in a vise.
c. Insert SST (1-A) and (1-B) into SST (2), and attach the pulley nut to SST (2).




d. To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn.

e. Remove the generator from SST (2).




f. Turn SST (1-B) and remove SST (1-A) and (1-B).
g. Remove the pulley nut and pulley.




2. REMOVE GENERATOR REAR END COVER
a. Place the generator on the pulley.
b. Remove the 3 nuts and rear end cover.




3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator from the rectifier end frame.




4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the 2 screws and brush holder.

5. REMOVE GENERATOR COIL ASSEMBLY




a. Remove the 4 bolts.




b. Using SST, remove the rectifier end frame.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)




6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the washer and rotor.

REASSEMBLY




1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the pulley.
b. Install the rotor and washer.

2. INSTALL GENERATOR RECTIFIER END FRAME




a. Using deep socket wrench 21 and a press, press in the coil carefully.




b. Tighten the 4 bolts.

Torque: 5.8 N.m(59 kgf.cm, 51 in.lbf)

3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY




a. While pushing the 2 brushes to the inside of the brush holder, insert a pin (dia.1.0 mm (0.039 in.)) into the brush holder hole.




b. Install the brush holder with the 2 screws.

Torque: 1.8 N.m(18 kgf.cm, 16 in.lbf)

c. Pull out the pin (dia.1.0 mm (0.039 in.)) from the brush holder.




4. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator.

NOTE: Pay attention to the mounting direction of the terminal insulator.




5. INSTALL GENERATOR REAR END COVER
a. Install the rear end cover with the 3 nuts.

Torque: 4.6 N.m(47 kgf.cm, 41 in.lbf)




6. INSTALL GENERATOR PULLEY

SST 09820-63010 (09820-06010, 09820-06020)




a. Install the pulley to the rotor shaft by tightening the generator pulley nut by hand.
b. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




c. Mount SST (2) in a vise.
d. Insert SST (1-A) and (1-B) into SST (2), and attach the generator pulley nut to SST (2).




e. Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration.

Torque: 133 N.m (1351 kgf.cm, 98 ft.lbf)

f. Remove the generator from SST (2).




g. Turn SST (1-B), and remove SST (1-A) and (1-B).
h. Turn the pulley, and check that the pulley moves smoothly.