Generator Disassembly and Reassembly: Disassembly

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

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: 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).
  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) 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).
  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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