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B6M0472A
5) Installing end frame
When assembling end frame to yoke, align notched portion
of end frame with lead wire grommet.
B6M0473A
6) Installing yoke
When installing yoke to magnetic switch, align notch of
yoke with protrusion of magnetic switch.
G6M0095
2. Generator
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0088
2) Disconnect connector and terminal from generator.
G2M0286
3) Remove V-belt cover.
4) Remove front side V-belt.
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6-1SERVICE PROCEDURE
1. Starter - 2. Generator
Page 1082 of 2248
G2M0090
5) Remove bolts which install generator onto bracket.
G2M0090
6) Installation is in the reverse order of removal.
CAUTION:
Check and adjust V-belt tension.
B6M0476A
B: DISASSEMBLY
1) Heat the portionAof rear cover to 50°C (122°F) with
heater drier.
G6M0065
2) Remove the four through bolts. Then insert the tip of a
flat-head screwdriver into the gap between the stator core
and front bracket. Pry then apart to disassemble.
G6M0066
3) Hold rotor with a vise and remove pulley nut.
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6-1SERVICE PROCEDURE
2. Generator
Page 1083 of 2248
B6M0477A
CAUTION:
When holding rotor with vise, insert aluminum plates
or wood pieces on the contact surfaces of the vise to
prevent rotor from damage.
B6M0478A
4) Remove rotor from front cover.
5) Remove three screws from front cover and then bear-
ing retainer and ball bearing.
B6M0479A
6) Remove bolt which secure battery terminal bolt, and
remove rear cover. Remove nuts which secure diode plate,
and remove stator and rear cover.
B6M0480A
7) Separate diode plate from stator coil.
(1) Cut the connecting position
Aof stator coil to
diode.
(2) Unsolder connection
Band throughout the lead
wire of stator coil.
B6M0481
(3) Remove stator coil from diode plate.
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6-1SERVICE PROCEDURE
2. Generator
Page 1084 of 2248
B6M0482
8) Remove bolts which secure IC regulator, diode and
brush holder.
CAUTION:
Do not apply a shock or load to IC regulator cooling
fins.
G6M0075
C: INSPECTION AND REPAIR
1. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of the
sliding surface.
Clean or polish with #500 to #600 emery paper if defective.
B6M0483A
2) Slip ring outside diameter
Measure slip ring outside diameter. If slip ring is worn,
replace rotor.
Slip ring outside diameter:
Standard
27 mm (1.06 in)
Limit
26 mm (1.02 in)
B6M0484A
3) Continuity test
Check continuity between slip rings. If continuity does not
exist, replace rotor.
B6M0485A
4) Insulation test
Check continuity between slip ring and rotor core or shaft.
If continuity exists, replace rotor.
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6-1SERVICE PROCEDURE
2. Generator
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B6M0486
5) Ball bearing
Check rear ball bearing. Replace it if it is noisy or if rotor
does not turn smoothly.
G6M0078
2. STATOR
1) Continuity test
Inspect stator coil for continuity between its terminals.
When there is no continuity between individual terminals,
cable is broken.
Replace stator coil.
G6M0079
2) Insulation test
Inspect stator coil for continuity between stator core and
each terminal. If there is continuity, replace stator coil.
B6M0487A
3. BRUSH
Measure brush length. If brush is worn, replace brush
holder assembly.
Brush length ():
Standard
20.5 mm (0.807 in)
Limit
1.5 mm (0.059 in)
B6M0488A
4. DIODE ASSEMBLY
The diode consists of eight diodes, four each being located
on the positive and negative sides. The diode is necessary
to restrict current flow to one direction.
Check all diodes, for continuity. If any diode is faulty,
replace diode assembly.
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6-1SERVICE PROCEDURE
2. Generator
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