GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01BAK6E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01BFQBE01

      Align the claws of the bearing retainer with the grooves inside the drive end frame.

    3. Install the bearing retainer with the 4 screws.

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Install the rotor and washer to the drive end frame.

    2. Install the generator washer to the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01BDIOE01

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

    2. A01BCW9

      Install the generator coil assembly with the 4 through bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01BBAEE01

      While pushing the 2 brushes to the inside of the generator brush holder assembly, insert a φ1.0 mm (0.039 in.) pin into the generator brush holder hole.

    2. A01BCF3E01

      Install the brush holder assembly with the 2 screws.

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

  5. INSTALL TERMINAL INSULATOR


    1. A01BI1H

      Install the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A01BGSF

      Install the end cover with the 3 nuts.

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

  7. INSTALL GENERATOR WITH CLUTCH PULLEY (w/ Clutch Pulley)


    1. Temporarily install the generator with clutch pulley by hand.

    2. Mount the generator in a vise between aluminum plates.

    3. A01BATDE03

      Install SST (A) and SST (B) to the generator with clutch pulley as shown in the illustration.

      SST
      09820-63020

      Note

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    4. A01BD29E03

      Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator with clutch pulley.

      Torque:
      without SST
      110 N*m  { 1125 kgf*cm, 81 ft.*lbf }
      with SST
      87 N*m  { 891 kgf*cm, 64 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 380 mm (14.96 in.)

      • Make sure SST and the wrench are connected in a straight line.

      Note

      Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    5. Remove SST from the generator.

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

    7. Install a new generator pulley cap.

  8. INSTALL GENERATOR PULLEY (w/o Clutch Pulley)


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

    2. Install SST (1-A) and (1-B) to the rotor shaft.

      SST
      09820-63010   ( 09820-06010, 09820-06020 )
      HINT:
      SST (1-A) and (1-B) 09820-06010
      SST 2 09820-06020
    3. A01BC13E01

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

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is secured to the generator rotor shaft.

    4. Mount the generator in a vise between aluminum plates.

    5. A01BDKLE01

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

    6. A01BAZ2E01

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

      Torque:
      110 N*m  { 1,125 kgf*cm, 81 ft.*lbf }

    7. Remove SST 2 from the generator.

    8. A01BE3VE01

      Turn SST (1-A), and remove SST (1-A) and (1-B).

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