Roller Bearing Removal

Press out worn bearing. Support end cover andpress on closed end of new bearing until it is flush with surface of end cover.

ASSEMBLING GENERATOR (Fig. 5E-1)

Assemble all parts to the brush holder mounting plate (13).

Position pole shoes (31) in field coils (32) and insert in frame. Turn in pole shoe screws until snug. Place frame in vise and use very large screwdriver to securely tighten screws. Use a wrench to turn screwdriver while bearing down with considerable force to keep screwdriver from slipping out of slots. Shoes will align themselves in frame.

Place bearing retainer (27) in inner groove in drive end plate (28). Press in bearing (26) to seat against retainer. Compress bearing retainer (25) with needle nose pliers and insert in outer groove.

Turn drive end plate back side up and press oil seal (29) in place. Insert armature (14) drive end shaft and press in until shoulder seats.

Slip "A" terminal field coil lead on positive terminal screw (24), followed by positive brush cable (23), a terminal screw bushing (20), bolt clip (19) and the terminal insulator (18). Insert the assembly through "A" terminal frame hole from inside. Assemble the insulating washer (17), lock washer (16) and nut

(15) over terminal screw.

Slip "F" terminal screw (22) into "F" terminal field coil lead, bracket insulator (21) and screw bushing (20). The assembly is then slipped into "F" terminal frame hole through the bolt clip and terminal insulator. An insulating washer (17), lock washer

(16) and nut (15) are assembled over terminal screw.

Slip frame assembly over armature, locating pin (48) in hole in drive end plate. Bend loose end of positive brush cable out commutator end of generator. Push brushes back in brush holders to clear commutator and assemble brush holder mounting plate over commutator so pin (48) registers in small slot and brush cable passes through large slot almost directly opposite.

Connect positive brush cable and positive brush lead to insulated brush holder terminal with washer (12) and nut (11). Connect grounded (negative) brush to its terminal in same manner.

Install commutator end cover (10) over armature shaft end so notch in edge registers over pin (48) in frame. Slip internal lock washer = over frame screws (9) and feed them through generator from drive end. Assemble lock washers (8) and nuts (7) to frame screws and tighten securely. Turn armature shaft to see if it is bound or if armature core strikes pole shoes. Shaft should be reasonably difficult to turn but there should be no tight spots. If armature core strikes pole shoes, generator ends are not seated properly or pole shoes are not drawn up tightly.

Slip drive end oil deflector (5), drive gear (4 or 4A) and washer (3) over shaft and turn on nut (2) until gear is seated against oil deflector. Install brush cover strap (6) with connection at bottom as positioned on motorcycle. Position gasket (1) coated with Perfect Seal No. 4 to generator and install in reverse order of disassembly as described in "Removing Generator."

fan cooled generator

The fan cooled generator is essentially the same as the standard, electrically, that is, it is a two-brush, shunt wound generator. Charge rate is governed by a current and voltage regulator. The difference is a larger physical size with higher current generating capacity, and it employs a fan to dissipate heat. Much of the technique used in testing the standard generator may be used in testing the fan cooled generator.

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