GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A00961PE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A009AMFE01
      Text in Illustration
      *1 Tab
      *2 Cutout

      Fit the tabs on the retainer plate into the cutouts on the 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. Install the generator rotor to the drive end frame.

    2. Place the generator washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A0098ATE07
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

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

    2. Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0094HWE20
      Text in Illustration
      *1 Pin

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

    2. A00979QE01
      Text in Illustration
      *1 Pin

      Install the generator brush holder to the generator coil 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.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A0094IH

      Install the terminal insulator to the generator coil.

      Note

      Make sure the terminal insulator is installed facing the proper direction.

  6. INSTALL GENERATOR REAR END COVER


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

      Torque:
      4.6 N*m  { 46 kgf*cm, 40 in.*lbf }

    2. Install the cord clip with the nut.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. Temporarily install the generator with clutch pulley by hand.

    2. Mount the generator in a vise between aluminum plates.

    3. A009808E01
      Text in Illustration
      *1 Rotor Shaft

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

      SST
      09820-63021

      Note

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    4. A0098VTE02
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      A009BSG Turn

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

      Note

      Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    5. Remove SST from the generator.

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

  8. INSTALL GENERATOR PULLEY CAP


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