GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. B006LPNN01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. B006RFKC01
      *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. Using a T25 "TORX" socket wrench, install the 4 screws.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 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 WITH RECTIFIER STATOR ASSEMBLY


    1. Install the generator with rectifier stator assembly with the 4 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  4. INSTALL GENERATOR REGULATOR ASSEMBLY


    1. B006LMWC01
      *a Pin (1.0 mm)

      While pushing the 2 brushes into the generator regulator assembly, insert a 1.0 mm (0.0394 in.) pin into the generator regulator assembly as shown in the illustration.

    2. B006LYHC01
      *a Pin (1.0 mm)
      B006REL Brush
      B006PCE Generator Regulator Assembly Cover
      B006QOD Push down
      B006LKF Pull out

      Push down the generator regulator assembly cover and secure the 2 brushes as shown in the illustration.

    3. Pull out the pin from the generator regulator assembly.

    4. B006N35C01
      B006QOD Push in

      Install the generator regulator assembly to the generator with rectifier stator assembly with the 2 bolts and stud bolt.

      Torque:
      4.3 N*m  { 44 kgf*cm, 38 in.*lbf }

    5. Push in the generator regulator assembly cover as shown in the illustration.

  5. INSTALL GENERATOR REAR END COVER


    1. Engage the 2 clamps and install the generator rear end cover to the generator coil assembly with the 2 nuts.

      Torque:
      3.3 N*m  { 34 kgf*cm, 29 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. B006QX9C01
      *1 Generator Pulley with Clutch

      Fit SST to the generator pulley with clutch.

      SST
      09820-30010
    4. B006RCIC01
      *a Rotor Shaft
      *b T45 "TORX" Socket Wrench

      Fit a T45 "TORX" socket wrench into the rotor shaft end.

    5. B006PYTC01
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold

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

      Torque:
      Specified tightening torque
      78.5 N*m  { 800 kgf*cm, 58 ft.*lbf }

      Tech Tips


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

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 73 N*m (744 kgf*cm, 54 ft.*lbf)

    6. Remove SST and the T45 "TORX" socket wrench from the generator pulley with clutch.

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

    8. Remove the generator assembly from the vise.

  7. INSTALL GENERATOR PULLEY CAP


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