Generac — Generator Disassembly

Repair & overhaul · AC Generator Assembly

From a Generac service manual covering: IM100G, IM80G, NP100G, NP80G. Check it applies to your exact model before use.

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Procedure

1. Remove the four capscrews, lockwashers and flatwashers that retain the REAR BEARING CARRIER PLATE to the REAR BEARING CARRIER. Remove the plate.
2. Remove the Rear Bearing Carrier GASKET.
3. Disconnect wires from BRUSH HOLDERS.
4. Remove SCREWS that retain the BRUSH HOLDERS to the Rear Bearing CARRIER. Remove the BRUSH HOLDERS.
5. Remove hardware that retains the Rear Bearing CARRIER to the generator mounting base.
6. Remove the four long CAPSCREWS and four LOCKWASHERS.
7. Use Rear Bearing Carrier PULLER tool (Part No. 74078) to free the Rear Bearing CARRIER from the Rotor bearing.
8. Free the STATOR ASSEMBLY from the BLOWER HOUSING and completely remove it.
9. Remove the hardware that retains the STARTER to the ENGINE PLATE. Remove the STARTER.
10. Remove all fasteners that retain the BLOWER HOUSING. Remove the BLOWER HOUSING.
11. Remove CAPSCREWS that retain the FLEX PLATE to the FAN & RING GEAR.
12. Remove the ROTOR ASSEMBLY with the FAN & RING GEAR attached.
13. Remove CAPSCREWS and LOCKWASHERS that retain the FLEX PLATE to the engine flywheel. Remove the FLEX PLATE.
14. To remove the FAN & RING GEAR from the ROTOR, remove CAPSCREW and LOCKWASHER, remove the SPACER, then remove the FAN & RING GEAR.

Source: Generac service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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