GENERATOR(for 100 A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01X481E01

      Using SST and a press, press in a new drive end frame bearing.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01X3ZKE01
      Text in Illustration
      *1 Tab
      *2 Cutout

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

    3. Install the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

    2. Place a new generator washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01X50FE07
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

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

    2. Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01X3CDE20
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

    2. A01X9J4E01
      Text in Illustration
      *1 Pin

      Install the brush holder 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 brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A01WZ7R

      Install the terminal insulator to the generator coil.

      Note

      Make sure the terminal insulator is installed facing the proper direction.

  6. INSTALL GENERATOR REAR END COVER


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

      Torque:
      4.6 N*m  { 46 kgf*cm, 40 in.*lbf }

    2. Install the cord clip with the nut.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  7. INSTALL GENERATOR PULLEY WITH CLUTCH


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

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

    3. A01X6AXE01
      Text in Illustration
      *1 Rotor Shaft

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

      SST
      09820-63021

      Note

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

    4. A01X5HKE02
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      B001XPG Turn

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Note

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

      Tech Tips


      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

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

    5. Remove SST from the generator.

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

  8. INSTALL GENERATOR PULLEY CAP


    1. Install a new generator pulley cap to the generator pulley with clutch.