GENERATOR REASSEMBLY

  1. INSTALL GENERATOR DRIVE END FRAME BEARING

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

      A011R9ZE01
      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )

    2. Fit the tabs on the bearing retainer into the cutouts on the drive end frame to install the bearing retainer.

      A011R4NE03
      Text in Illustration
      *a Tab
      *b Cutout

    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.

      A011SRW

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

    3. Place a new generator washer on the generator rotor.

      A011UMXE01

  3. INSTALL GENERATOR COIL ASSEMBLY

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

      A011UCEE02
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

    2. Install the 4 bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      A011V8C

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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

      A011UX3E18
      Text in Illustration
      *1 Pin

    2. Install the generator brush holder with the 2 screws.

      A011SEME02
      Text in Illustration
      *1 Pin
      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    3. Pull the pin out of the generator brush holder.

  5. INSTALL GENERATOR REAR END COVER

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

      A011THS

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

      A011VA4
      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }

  6. INSTALL GENERATOR PULLEY WITH CLUTCH

    1. Temporarily install the generator pulley by hand.

    2. Mount the generator in a vise.

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

      A011QYGE02
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      SST
      09820-63021

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

      A011QUUE01
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      *a

      Fulcrum Length

      100 mm (3.94 in.)
      *b

      Fulcrum Length

      255 mm (10.04 in.)
      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note

      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.04 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench

      • Check that the drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    5. Check that the generator pulley rotates smoothly.

  7. INSTALL GENERATOR PULLEY CAP

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

      A011T1R