GENERATOR REASSEMBLY

  1. INSTALL GENERATOR DRIVE END FRAME BEARING

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

      A011SUPE01
      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )

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

      A011UTEE04
      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 drive end frame on the generator pulley with clutch.

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

      A011U9DE01

  3. INSTALL GENERATOR PULLEY WITH CLUTCH

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

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

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

      A011T6HE03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      SST
      09820-63021

    4. Place the rotor shaft end into SST (A).

      A011UL3E02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

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

      A011RP8E02
      Text in Illustration
      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)

    6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.

      A011RJ5E02
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *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.

    7. Remove SST from the generator assembly.

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

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

  4. INSTALL GENERATOR COIL ASSEMBLY

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

      A011QPXE01

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

      A011TTZE05
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

    3. Install the 4 bolts.

      A011RPJ
      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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

      A011UX3E18
      Text in Illustration
      *1 Pin

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

      A011QZGE05
      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

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

      Text in Illustration
      *1 Pin

  6. INSTALL GENERATOR TERMINAL INSULATOR

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

      A011U10E01

      Note

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

  7. INSTALL GENERATOR REAR END COVER

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

      A011SIX
      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }