GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


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

    2. A017EDBE01

      Install the generator rotor assembly to the drive end frame.

    3. A017GADE01

      Place a new generator washer on the generator rotor.

  2. INSTALL GENERATOR COIL ASSEMBLY


    1. A017CL9E01

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

    2. A017F43

      Install the 4 bolts.

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

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A017ENEE13

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

    2. A017BFWE04

      Install the brush holder assembly to the generator coil 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.

  4. INSTALL GENERATOR TERMINAL INSULATOR


    1. A017FK2E01

      Install the terminal insulator to the generator coil.

      Note

      Pay attention to the installation direction of the terminal insulator.

  5. INSTALL GENERATOR REAR END COVER


    1. A017FFO

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

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

  6. INSTALL GENERATOR CLUTCH PULLEY


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

    2. A017FLNE01

      Set SST (A) and (B).

      SST
      09820-63020
    3. A017F6HE01

      Clamp SST (A) in a vise.

      Note

      Be sure to fix the flat surface of SST (A) in a vise.

    4. A017BBNE01

      Place the rotor shaft end into SST (A).

    5. A017BAME01

      Fit SST (B) to the clutch pulley.

    6. A017F90E01

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

      Torque:
      w/o SST
      110 N*m  { 1125 kgf*cm, 81 ft.*lbf }
      w/ SST
      84 N*m  { 857 kgf*cm, 62 ft.*lbf }

      Note


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

      • This torque value is effective when SST is parallel to a torque wrench.

      • Hold the generator assembly tightly.

    7. Remove the generator assembly from SST.

    8. Check that the clutch pulley rotates smoothly.

    9. Install a new clutch pulley cap to the clutch pulley.