GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the drive end frame on the clutch pulley.

    2. A01CFVAE01

      Install the generator rotor assembly to the drive end frame.

    3. A01CD6OE01

      Place a new generator washer on the generator rotor.

  2. INSTALL GENERATOR CLUTCH PULLEY


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

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

    3. A01CG6YE02

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

      SST
      09820-63021
    4. A01CG9PE01

      Place the rotor shaft end into SST (A).

    5. A01CCNOE01

      Fit SST (B) to the clutch pulley.

    6. A01CCVEE13

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 255 mm (10.0 in.).

      • This torque value is effective when SST is parallel to the torque wrench.

      • Check that the drive end frame secure in the vise tightly.

      • Hold the SST (A) tightly during the operation.

    7. Remove the generator assembly from SST.

    8. Check that the clutch pulley rotates smoothly.

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01CGJEE03

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

    2. A01CBG1

      Install the 4 bolts.

      Torque:
      5.8 N*m  { 59 kgf*cm, 51 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01CEIZE13

      While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.039 in.) pin into the brush holder hole.

    2. A01CG3IE02

      Install the brush holder assembly 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. A01CFMZE01

      Install the terminal insulator to the generator coil.

      Note

      Pay attention to installation direction of the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A01CCZO

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

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