Disassembly and Assembly

DISASSEMBLY







Generator - Exploded View

1. Make an alignment mark on the generator front housing and generator rear housing and bearing and stator and coil for proper assembly alignment.







2. Remove the four generator front housing capscrews.







3. Use a 200-watt soldering iron to heat the generator rear housing and bearing to allow the generator rear bearing to be removed from the generator rear housing.

CAUTION: Do not apply excessive direct heat to the generator rear housing and bearing. Excessive heat could cause the generator rear bearing grease to melt.

NOTE: Do not apply the soldering iron for more than four minutes. Do not heat the generator rear housing and bearing to temperatures higher than 50-60°C (122-140°F).







4. Use a flat-blade screwdriver to separate the generator front housing from the stator and coil.







5. Remove the generator front housing and generator rotor with the generator rear bearing pressed on from the generator rear housing.

NOTE: Be careful not to lose the stopper ring that fits in the groove of the generator rotor shaft.

6. Secure the generator rotor in a soft-jawed vise and remove the generator pulley nut.
7. Remove the generator pulley lockwasher and generator pulley.
8. Remove the generator rotor from the generator front housing.
9. Remove the four bearing retainer screws.
10. Remove the bearing retainer.
11. Use an appropriate socket or driver that fits the outer bearing race to press the generator front bearing out of the generator front housing.







12. Use Bearing Pulling Attachment D84L-1122-A or equivalent and a suitable socket to press the generator rear bearing from the generator rotor.







13. Remove the B-terminal nut and insulator.
14. Remove the rectifier screw.







15. Remove the two voltage regulator screws.







16. Use a flat-blade screwdriver to separate the stator and coil from the generator rear housing.
17. Remove the stator and coil, along with the Voltage Regulator (VR) and rectifier, from the generator rear housing.
18. Remove the shield from the VR.
19. Unsolder the stator and coil leads from the generator rear housing.

CAUTION: To avoid overheating and damage to the rectifier, work quickly while soldering. Do not apply the soldering iron for more than five seconds at a time.

20. Unsolder the VR leads.
21. Separate the rectifier, stator and coil, and VR.
22. Inspect all components. See Cleaning and Inspection. Testing and Inspection
23. Refer to diagnosis and testing procedures. Testing and Inspection

ASSEMBLY
1. Assemble the rectifier, stator and coil, and VR.
2. Solder the VR leads.

CAUTION: Use only rosin-core solder. Do not apply soldering heat for longer than four seconds. Hold the stator and coil leads with a pair of needlenose pliers which will act as a heat sink to protect the diodes.

3. Solder the stator and coil leads.
4. Install the shield onto the VR.
5. Install the stator and coil, along with the rectifier and VR, to the generator rear housing.







6. Position the stator and coil in the generator rear housing so that one of the shallow ridges in the lamination lines up with the case bolt holes.
7. Install the rectifier screw.
8. Install the two VR screws.
9. Install the insulator and the B-terminal nut.







10. Use a suitable socket or bearing installer to fit the outer bearing race, then use a vise and press the generator front bearing into the generator front housing.
11. Position the bearing retainer and install the four bearing retainer screws.







12. Use a suitable driver on the inner bearing race to press the generator rear bearing onto the generator rotor shaft.

CAUTION: Make certain that the stopper ring is installed in the groove in the generator rear bearing.

NOTE: Install the generator rear bearing so that the stopper ring is located on the inner side, toward the slip rings.

13. Place the generator rotor into the generator front housing.
14. Install the generator pulley and the generator pulley lockwasher.
15. Secure the generator rotor in a soft-jawed vise and install the generator pulley nut. Tighten the generator pulley nut to 59-78 N.m (43-58 lb-ft).







16. Use a stiff wire or straightened paper clip to retain the brushes in the VR.
17. Use the alignment marks made during disassembly to position the generator front housing, the stator and coil and generator rear housing.
18. Install the four generator front housing capscrews. Tighten the four generator front housing capscrews to 4-5 N.m (35-48 lb-in).
19. Remove the stiff wire or paper clip holding the generator brushes in the VR.
20. Rotate the generator pulley manually through a full 360 degrees to check for ease of rotation.
21. If the generator rotor drags or does not turn easily, disassemble the Generator (GEN) to determine the cause.