GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01XK4XE01

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. A01XGK8E02
      Text in Illustration
      *1 Claw

      Align the claws of the bearing retainer with the grooves inside the generator drive end frame.

    3. Install the bearing retainer with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Install the rotor and washer to the drive end frame.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01XIPOE03
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

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

    2. A01XKQA

      Install the generator coil with the 4 through bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01XDAHE06
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the generator brush holder, insert a φ1.0 mm (0.0394 in.) pin into the generator brush holder hole.

    2. A01XGY3E05
      Text in Illustration
      *1 Pin

      Install the brush holder 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

    A01XE99

  6. INSTALL GENERATOR REAR END COVER


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

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

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. Install the pulley by hand.

    2. Mount generator in a vise between aluminum plates.

    3. A01XI7GE03

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

      SST
      09820-63021

      Note

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

    4. A01XKQQE02
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      B001CHY Turn

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

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 81 ft.*lbf }
      with SST
      83 N*m  { 844 kgf*cm, 61 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 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.

      Note

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

    5. Remove SST from the generator.

    6. Check that the generator pulley rotates smoothly.

    7. Install a new generator pulley cap.