GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. B000MKSE01

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. B000MMEE04
      Text in Illustration
      *a Tab
      *b Cutout

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

    3. Install the 4 screws.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the generator drive end frame on the generator pulley with clutch.

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. B000M9CE01
      Text in Illustration
      *a Protrusion
      *b Groove

      Install a new bearing cover packing.

      Note

      Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

    2. B000IL7E05
      Text in Illustration
      *a 21 mm Deep Socket Wrench

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

    3. Install the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. B000H1KE30
      Text in Illustration
      *a Pin (1.0 mm)

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

    2. B000HFIE07
      Text in Illustration
      *a Pin

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

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

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

  5. INSTALL GENERATOR REAR END COVER


    1. Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator in the correct direction.

    2. Install the generator rear end cover to the generator coil assembly with the 3 bolts.

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

  6. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Secure the generator assembly in a vise between aluminum plates.

    2. Temporarily install the generator pulley with clutch to the rotor shaft.

    3. B000H14E04
      Text in Illustration
      *a Rotor Shaft

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

      SST
      09820-63021
    4. B000H22E01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

      Torque:
      Specified tightening torque
      111 N*m  { 1132 kgf*cm, 82 ft.*lbf }

      Note


      • Check that the generator assembly is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.7 in.)): 89 N*m (908 kgf*cm, 66 ft.*lbf)

    5. Remove SST (A) and (B) from the generator pulley with clutch.

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

    7. Remove the generator assembly from the vise.