Starting System & Charging System: Generator: Disassembly: Notes

1. Remove the rear cover.
   Fig 1: Locating Rear Cover Nuts

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2. Remove the bushing from the terminal B.
   Fig 2: Locating Bushing From Terminal B

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3. Remove the brush assembly.
   Fig 3: Locating Brush Assembly Screws

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4. Remove the through bolt.
   Fig 4: Locating Brush Assembly Through Bolts

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5. Insert a flat tip screwdriver or similar tool wrapped with protective tape into the gap between stator core and the front cover, and remove the stator coil assembly from the rotor assembly.
   CAUTION:

   • Be careful not to deform or damage the parts during operation.
   • Disassemble while lifting the entire stator coil assembly evenly.
   Fig 5: Inserting Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover

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6. Remove the bearing cover from the stator coil assembly.
   CAUTION: Do not reuse the bearing cover.
   Fig 6: Locating Bearing Cover From Stator Coil Assembly

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7. Using a vise, secure the rotor assembly.
   CAUTION:

   • Place aluminum plates or wooden pieces between the contacting surfaces of the vise and rotor to prevent rotor damage.
   • Be sure to hold it with the wider surface of the pole core.
   • Do not tighten the vise more than necessary.
   Fig 7: Securing Rotor Assembly Using Vise

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8. Using a thin flat tip screwdriver, break and remove the dust cover.
   Fig 8: Removing Dust Cover

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9. Remove the pulley.
   Fig 9: Removing Pulley

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10. Remove the front cover from the rotor assembly.
    NOTE: If it is stuck, use a press to remove.
    Fig 10: Removing Front Cover From Rotor Assembly

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11. Remove the bearing retainer from the front cover.
    NOTE: The following procedures from here are not necessary to be performed if bearing replacement is not required.
    Fig 11: Locating Bearing Retainer From Front Cover

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12. Use the press to remove the ball bearing from the front cover.

CAUTION: Press the inner race of bearing using an attachment, etc. suitable for the press.

Fig 12: Pressing Inner Race Of Bearing

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