Generator Disassembly and Reassembly: Disassembly

For easier reinstallation, provide match marks (3) on drive end frame (1) and rear end frame (2) as shown.

Fig 1: Identifying Matching Marks On Drive End Frame And Rear End Frame
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Remove end frame bolts (1) from generator.

Fig 2: Removing End Frame Bolts From Generator
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With lever (1) inserted between stator core (2) and drive end frame (3), separate generator into drive end frame (3) and rear side.

Fig 3: Inserting Between Stator Core And Drive End Frame
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Remove pulley as follows.
- M/T model
  1. Hold rotor (2) using vise (4).
    CAUTION:
    When using vise (4), put clean cloth (3) between rotor (2) and vise (4) so as not to cause damage to rotor (2).
    
    Be sure to hold the location A. Do not hold the location B as it does not have enough structural strength.
  2. Loosen pulley nut and remove pulley (1).
    
    Fig 4: Identifying Pulley Nut And Pulley
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- CVT model
  1. Hold rotor (2) using vise (4).
    NOTE:
    When using vise (4), put clean cloth (3) between rotor (2) and vise (4) so as not to cause damage to rotor (2).
    
    Be sure to hold the location A. Do not hold the location B as it does not have enough structural strength.
  2. Remove pulley (1) using special tool.
    Special Tool
    
    (A): 09932-96510
    
    Fig 5: Removing Pulley Using Special Tool
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Remove drive end frame from rotor.
Remove bearing retainer screws (1) and bearing retainer.

Fig 6: Removing Bearing Retainer Screws And Bearing Retainer
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Remove drive end bearing from drive end frame (1) using special tool and hydraulic press (2).
Special Tool

(A): 09943-88211

Fig 7: Removing Drive End Bearing From Drive End Frame Using Special Tool And Hydraulic Press
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Remove rear end bearing (1) using hydraulic press (2), general rod (3) and general tool (4).

Fig 8: Removing Rear End Bearing Using Hydraulic Press General Rod And General Tool
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Remove three screws (1) and generator "B" terminal nut (2).

Fig 9: Removing Three Screws And Generator "B" Terminal Nut
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Remove stator with IC regulator assembly and rectifier assembly from rear end frame.
Unsolder stator leads (1) and remove stator (2) from rectifier assembly.

Fig 10: Identifying Stator Leads And Stator
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To remove brush, remove holder (1) from brush holder (2) and then disconnect brush wire (3) from regulator terminal using soldering iron.

Fig 11: Removing Brush And Brush Holder
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