GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A01ELIU

      Place the generator drive end frame on the generator pulley.

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

    3. A01EIXFE01

      Place the washer on the generator rotor.

  2. INSTALL GENERATOR COIL ASSEMBLY


    1. A01EJIJE02
      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. A01EMCC

      Install the 4 bolts.

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

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01EKBLE18
      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. A01ELDAE02
      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.

  4. INSTALL GENERATOR REAR END COVER


    1. A01EJ6T

      Install the terminal insulator onto the generator coil assembly.

    2. A01EKSS

      Install the generator rear end cover with the 3 nuts.

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

  5. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Temporarily install the generator pulley by hand.

    2. Mount the generator in a vise.

    3. A01ELTVE02
      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. A01EMEVE02
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      *3 Fulcrum Length

      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
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 260 mm (10.24 in.).

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

  6. INSTALL GENERATOR PULLEY CAP


    1. A01ELY5

      Install a new generator pulley cap to the pulley.