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. A01CG6YE03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021
    4. A01CBD9E02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. A01CEVSE02
      Text in Illustration
      *1 Clutch Pulley
      *2 SST (A)
      *3 SST (B)

      Fit SST (B) to the clutch pulley.

    6. A01CCVEE03
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *3 Fulcrum Length 255 mm

      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 is secured in the vise tightly.

      • Hold 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 generator pulley cap to the clutch pulley.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01CBY5E04

      Using SST and a press, press in the generator coil assembly to the drive end frame.

      SST
      09612-70100   ( 09612-07240 )
    2. A01CFY2

      Install the cord clip with the bolt.

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }
    3. A01CC6C

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01CEIZE18
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.0394 in.) pin into the brush holder hole.

    2. A01CFDF

      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. A01CFQBE03
      Text in Illustration
      *1 Pin
      *2 Pull out

      Pull out the pin from the generator brush holder.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01CG0U

      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. A01CDMX

      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 }