GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   
   

   1. 

      Using SST and a press, press in a new generator drive end frame bearing.

      SST

      09950-60010   ( 09951-00470 )

      09950-70010   ( 09951-07100 )

   2. 

      Text in Illustration

      *a	Tab
      *b	Cutout

      Fit the tabs on the bearing retainer into the cutouts on the generator drive end frame to install the bearing retainer.

   3. Install the 4 screws.

      Torque:

      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

2. INSTALL GENERATOR ROTOR ASSEMBLY

   
   

   1. Place the generator drive end frame on the generator pulley with clutch.

   2. 

      Install the generator rotor assembly to the generator drive end frame.

3. INSTALL GENERATOR PULLEY WITH CLUTCH

   
   

   1. Temporarily install the generator pulley with clutch onto the rotor shaft.

   2. Mount the generator drive end frame in a vise tightly.

   3. 

      Text in Illustration

      *1	SST (A)
      *2	SST (B)

      Confirm SST (A) and (B) shown in the illustration.

      SST

      09820-63021

   4. 

      Text in Illustration

      *1	Rotor Shaft
      *2	SST (A)

      Place the rotor shaft end into SST (A).

   5. 

      Text in Illustration

      *1	Generator Pulley with Clutch
      *2	SST (B)
      *3	SST (A)

      Fit SST (B) to the generator pulley with clutch.

   6. 

      Text in Illustration

      *1	SST (B)
      *2	SST (A)
      *a	Fulcrum Length 100 mm (3.94 in.)
      *b	Fulcrum Length 255 mm (10.0 in.)

      Tighten the generator pulley with clutch by turning SST (B) in the direction shown in the illustration.

      Torque:

      without SST

      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      with SST

      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note

      
      

      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.0 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

      • Check that the generator drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

   7. Remove SST from the generator assembly.

   8. Check that the generator pulley with clutch rotates smoothly.

4. INSTALL GENERATOR PULLEY CAP

   
   

   1. Install a new generator pulley cap to the generator pulley with clutch.

5. INSTALL GENERATOR COIL ASSEMBLY

   
   

   1. 

      Place a new generator washer on the generator rotor assembly.

   2. 

      Text in Illustration

      *1	Deep Socket Wrench (21 mm)

      Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.

   3. 

      Install the 4 bolts.

      Torque:

      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

6. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   
   
   1. 

      Text in Illustration

      *1

      Pin

      While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the brush holder hole.

   2. 

      Text in Illustration

      *1

      Pin

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

      Torque:

      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

   3. Pull out the pin from the generator brush holder assembly.

7. INSTALL GENERATOR TERMINAL INSULATOR

   
   

   1. 

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator in the correct direction.

8. INSTALL GENERATOR REAR END COVER

   
   

   1. 

      Install the generator rear end cover with the 3 nuts.

      Torque:

      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }