GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   
   

   1. 

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

      SST

      09950-60010   ( 09951-00470 )

      09950-70010   ( 09951-07100 )

   2. 

      *a	Tab
      *b	Cutout

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

   3. Install the 4 screws.

      Torque:

      2.3 N*m  { 23 kgf*cm, 20 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 PULLEY WITH CLUTCH

   
   

   1. Temporarily install the generator pulley with clutch onto the rotor shaft.

   2. Secure the generator drive end frame in a vise tightly.

   3. 

      Confirm SST (A) and (B) shown in the illustration.

      SST

      09820-63021

   4. 

      *a	Rotor Shaft

      Place the rotor shaft end into SST (A).

   5. 

      *1	Generator Pulley with Clutch

      Fit SST (B) to the generator pulley with clutch.

   6. 

      *a	Length of SST 100 mm (3.94 in.)
      *b	Length of Torque Wrench 400 mm (1.312 ft.)
      *c	Hold
      	Turn

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

      Torque:

      without SST [Torque (N*m(kgf*cm, ft.*lbf))]

      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      with SST [Reading of Torque wrench (N*m(kgf*cm, ft.*lbf))]

      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips

      
      

      • This torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 400 mm (1.312 ft.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Click here

   7. Remove SST from the generator assembly.

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

4. INSTALL GENERATOR PULLEY CAP

   
   

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

5. INSTALL GENERATOR COIL ASSEMBLY

   
   

   1. 

      *a	21 mm Deep Socket Wrench

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

   2. 

      Install the 4 bolts.

      Torque:

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

6. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   
   
   1. 

      *a	Pin (1.0 mm)

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

   2. 

      *a	Pin (1.0 mm)

      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.

7. INSTALL GENERATOR TERMINAL INSULATOR

   
   

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

      Note

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

8. INSTALL GENERATOR REAR END COVER

   
   

   1. 

      Install the generator rear end cover with the 3 nuts.

      Torque:

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