GENERATOR REASSEMBLY


  1. INSTALL BRUSH

    A01KIQ3

    1. Run the wire to a new brush through the spring and the hole in the holder, and insert the spring and brush into the holder.

    2. Solder the brush wire to the holder at the specified exposed length.

      Exposed length
      9.5 - 11.5 mm (0.374 - 0.453 in.)

    3. Check that the brush moves smoothly.

    4. Cut off the excess wire.

    5. Apply insulation paint to the soldered area.

  2. INSTALL ROTOR BEARING (Front)

    A01KEHZ

    1. Using SST and a press, press in a new bearing.

      SST
      09950-60010   ( 09951-00280 )
      09950-70010   ( 09951-07100 )

    2. Install the bearing retainer with the 4 bolts.

      Torque:
      2.6 N*m  { 7 kgf*cm, 23 ft.*lbf }

  3. INSTALL ROTOR BEARING (Rear)


    1. Install the bearing cover (inside).

    2. A01KGRP

      Using SST and a press, press in a new bearing.

      SST
      09820-00030
    3. A01KECQ

      Using SST, push in the bearing cover (outside).

      SST
      09285-76010

  4. INSTALL GENERATOR ROTOR ASSEMBLY

  5. INSTALL RECTIFIER END FRAME


    1. Place the generator washer on the rotor.

    2. A01KHCIE01
      Text in Illustration
      *1 29 mm socket wrench

      Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.

    3. A01KIFDE01
      Text in Illustration
      *1 Cord Clip

      Install the cord clip and 4 nuts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf, for nut A }
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf, for nut B }

  6. INSTALL GENERATOR HOLDER W/RECTIFIER

    A01KIE2

    1. Install the rectifier holder with the 4 screws.

      Torque:
      1.96 N*m  { 20 kgf*cm, 17 in.*lbf }

  7. INSTALL GENERATOR REGULATOR ASSEMBLY

    A01KHW1E01

    1. Install the regulator and 3 screws.

      Torque:
      1.96 N*m  { 20 kgf*cm, 17 in.*lbf }

  8. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A01KG7KE01

    1. Install the brush holder cover.

      Text in Illustration
      *a Upward

      Note

      Be careful brush holder direction.

    2. A01KH9QE01

      Install the brush holder and 2 screws.

      Torque:
      1.96 N*m  { 20 kgf*cm, 17 in.*lbf }

      Note

      Be careful of the holder installation direction.

  9. INSTALL REAR END COVER

    A01KF88

    1. Install the end cover and plate terminal with the bolt and 3 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf, for nut }
      3.9 N*m  { 40 kgf*cm, 34 in.*lbf, for bolt }

    2. Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

  10. INSTALL GENERATOR W/CLUTCH PULLEY


    1. Install the pulley by hand.

    2. A01KFVJE08

      Install SST to the pulley and vise as shown in the illustration.

      SST
      09820-63021   ( 09821-63011, 09821-63020 )
    3. A01KGPAE01

      Turn SST (B) counterclockwise, tighten the pulley.

      SST
      09820-63021   ( 09821-63011, 09821-63020 )
      Torque:
      110.5 N*m  { 1125 kgf*cm, 81 ft.*lbf }

  11. INSPECT ROTOR BEARING


    1. Check that rotor rotates smoothly.