GENERATOR (for 80A Type) REASSEMBLY


  1. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01CGVWE01
      Text in Illustration
      *1 Pin

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

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

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    3. A01CJDKE01
      Text in Illustration
      *1 Pin

      Pull out the pin from the generator brush holder assembly.

  2. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01CGQA

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Make sure that the generator terminal insulator is oriented as shown in the illustration.

  3. INSTALL GENERATOR REAR END COVER


    1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.

      Torque:
      4.6 N*m  { 46 kgf*cm, 40 in.*lbf }

  4. INSTALL GENERATOR PULLEY


    1. Mount the generator assembly in a vise between aluminum plates.

    2. Install the generator pulley to the generator rotor shaft by tightening the generator pulley nut by hand.

    3. A01CIB8E01

      Install SST 1-A and SST 1-B to the generator pulley as shown in the illustration.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )

      Tech Tips

      SST 1-A and B 09820-06010
      SST 2 09820-06021

    4. Hold SST 1-A with a torque wrench and tighten SST 1-B clockwise to the specified torque.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

    5. A01CIW5E01

      Insert SST 2 and attach it to the generator pulley nut.

      Text in Illustration
      A01CHW8 Insert
    6. A01CI4IE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.

      Torque:
      133 N*m  { 1351 kgf*cm, 98 ft.*lbf }

      Tech Tips

      Hold the adjustable wrench against the vise and tighten the nut securely.

    7. Remove SST 2 from the generator assembly.

    8. A01CHSZE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Turn SST 1-B in the direction shown in the illustration, and then remove SST 1-A and SST 1-B.

    9. Turn the generator pulley and check that the generator pulley moves smoothly.