GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01HN3VE01

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. A01HPQHE03
      Text in Illustration
      *a Tab
      *b Cutout

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

    3. Install the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A01HOKZ

      Place the generator drive end frame on the generator pulley.

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

    3. A01HQPHE01

      Place a new generator washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01HOW1E02
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

      Using a 21 mm socket wrench and a press, slowly press in the generator coil.

    2. A01HP1E

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01HMUPE18
      Text in Illustration
      *1 Pin

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

    2. A01HQYGE02
      Text in Illustration
      *1 Pin

      Install the generator brush holder with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    3. Pull the pin out of the generator brush holder.

  5. INSTALL GENERATOR REAR END COVER


    1. A01HOUA

      Install the terminal insulator onto the generator coil assembly.

    2. A01HP4O

      Install the generator rear end cover with the 3 nuts.

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

  6. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Temporarily install the generator pulley by hand.

    2. Mount the generator in a vise.

    3. A01HMHLE02
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021
    4. A01HOTRE01
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      *a

      Fulcrum Length

      100 mm (3.94 in.)
      *b

      Fulcrum Length

      255 mm (10.04 in.)

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.04 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench

      • Check that the drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    5. Check that the generator pulley rotates smoothly.

  7. INSTALL GENERATOR PULLEY CAP


    1. A01HO8H

      Install a new generator pulley cap to the pulley.