Remove the nut and disconnect the wire harness from terminal B. Separate the 2 wire harness clamps. Remove the 2 bolts and generator assembly. Remove the bolt and remove the wire harness clamp bracket. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
SST c. Clamp SST A in a vise. NOTE: Do not reuse the generator pulley cap. Place the rotor shaft end into SST A. Fit SST B to the clutch pulley. Loosen the pulley by turning SST B in the direction shown in the illustration.
Remove the generator assembly from the SST. Remove the clutch pulley from the rotor shaft. Place the generator assembly on the clutch pulley. Remove the 3 nuts and generator rear end cover. Remove the terminal insulator. Remove the 2 screws and generator brush holder. Remove the 4 bolts. Remove the bolt and cord clip. Using SST, remove the coil. SST , , , , , , Fig.
Remove the washer. Remove the generator rotor. Remove the 4 screws and bearing retainer. Using SST and a hammer, tap out the bearing. SST , Fig. Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.
If the result is not as specified, replace the generator clutch pulley. Using vernier calipers, measure the brush length. Standard length: 9. Minimum length: 4. If the brush length is less than the minimum, replace the generator brush holder assembly. Check the appearance. Check that the bearing is not rough or worn. OK: The bearing rotates smoothly.
If the result is not as specified, replace the generator rotor assembly. Check the resistance. Measure the resistance between the slip rings. Measure the resistance between the slip ring and rotor core.
Check the slip ring diameter. Using vernier calipers, measure the slip ring diameter. Standard diameter: Minimum diameter: 14 mm 0. If the diameter is less than the minimum, replace the generator rotor assembly. If the bearing does not rotate smoothly, replace the bearing.
Using SST and a press, press in a new generator drive end frame bearing. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate. Install the 4 screws. Torque: 2. Place the drive end frame on the clutch pulley.
Install the generator rotor onto the generator rectifier end frame. Place a new generator washer on the generator rotor. Using SST and a press, press in the generator coil assembly to the drive end frame.
SST Fig. Tighten the 4 bolts. Torque: 5. Install the cord clip with the bolt. Torque: 4. While pushing the 2 brushes into the generator brush holder, insert a 1. Install the generator brush holder with the 2 screws. Torque: 1.
Pull the pin out of the generator brush holder. Install the terminal insulator onto the generator rectifier end frame. Install the generator rear end cover with the 3 nuts. Temporarily install the clutch pulley onto the rotor shaft. Tighten the pulley by turning SST B in the direction shown in the illustration. Check that the clutch pulley rotates smoothly. Install a new clutch pulley cap to the clutch pulley. Install the wire harness clamp bracket with the bolt.
Torque: 8. Install the generator assembly with the 2 bolts. Install the generator wire to terminal B with the nut. Torque: 9. Attach the clamp and connect the generator connector to the generator. Hello Thank you very much for your patience.
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