GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A0028EZE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A0028IAC02
      *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:
      2.3 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 to the rotor shaft.

    2. Secure the generator drive end frame in a vise between aluminum plates.

    3. A002A7FC01
      *a Rotor Shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021

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

    5. A002CNCC01
      *a Hold
      *b Turn
      *c Length of SST 100 mm (3.94 in.)
      *d Length of Torque Wrench 400 mm (1.31 ft.)

      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


      • The "with SST" 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 (1.31 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

    6. Remove SST from the generator pulley with clutch.

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

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. Place a new washer on the generator rotor assembly.

    2. A002C4XC01
      *a 21 mm Socket Wrench

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

    3. Install the 4 bolts.

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

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0029TEC12
      *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. A002740C04
      *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 hole.

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A0027MS

      Install the generator terminal insulator to the generator coil assembly.

      Note

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

  7. INSTALL GENERATOR REAR END COVER


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

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

  8. INSTALL GENERATOR PULLEY CAP


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