GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A003HH8

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A003AZCE01

      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.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A003F9GE01

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

    2. A003G1Y

      Install the generator coil assembly with the 4 through bolts.

      Torque:
      5.8 N*m  { 59 kgf*cm, 51 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A003FEQE01

      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. A003I3RE01

      Install the brush holder assembly with the 2 screws.

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

  5. INSTALL TERMINAL INSULATOR


    1. A003BOW

      Install the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A003AN6

      Install the generator rear end cover with the 3 nuts.

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

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. Install the pulley by hand.

    2. A003BNLE01

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

      SST
      09820-63020
    3. A003HQ0E01

      Turn SST (B) counterclockwise, and tighten the pulley.

      SST
      09820-63020
      Torque:
      87 N*m  { 891 kgf*cm, 64 ft.*lbf }

      Note

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

    4. Check that the generator pulley rotates smoothly.

    5. Install the generator pulley cap.