GENERATOR(for TMMF Made) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01VICAE01

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

      SST
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )
    2. A01VIFDE01
      Text in Illustration
      *a Tab
      *b Cutout

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

    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 clutch pulley.

    2. A01VH9E

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

    3. A01VLY5

      Install a new generator washer on the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01VHEPE01

      Using SST and a press, slowly press in the generator coil assembly.

      SST
      09612-70100   ( 09612-07240 )
    2. A01VJ8I

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VEI3E10
      Text in Illustration
      *1 Pin (φ1.0 mm)

      While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.0394 in.) pin into the brush holder hole.

    2. A01VLKY

      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. A01VL1CE01
      Text in Illustration
      *1 Pin (φ1.0 mm)

      Pull out the pin from the generator brush holder hole.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01VJTD

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Pay attention to the installation direction of the generator terminal insulator as shown in the illustration.

  6. INSTALL GENERATOR REAR END COVER


    1. A01VFWZ

      Install the generator rear end cover onto the generator coil assembly with the 3 bolts.

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

  7. INSTALL GENERATOR CLUTCH PULLEY

    A01VJVGE01
    Text in Illustration
    *1 Rotor Shaft

    1. Clamp the generator housing stay in a vise tightly.

    2. Temporarily install the generator clutch pulley onto the rotor shaft.

    3. Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A01VJRQE01
      Text in Illustration
      *1 Generator Clutch Pulley

      Fit SST(B) to the generator clutch pulley.

    5. A01VJDUE03
      Text in Illustration
      *a Turn
      *b Hold
      *c Length 100 mm
      *d Length 318 mm

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

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 82 ft.*lbf }
      with SST
      84 N*m  { 857 kgf*cm, 62 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).

      • This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

    6. Remove SST from the generator assembly.

    7. Check that the generator clutch pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


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

  9. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamps bracket with bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Remove the generator assembly from a vise.