GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   
   

   1. 

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

      SST

      09950-60010   ( 09951-00470 )

      09950-70010   ( 09951-07100 )

   2. 

      *a	Tab
      *b	Cutout

      Fit the tabs of the retainer plate into the cutouts of the generator 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. Place the generator drive end frame on the generator pulley with clutch.

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

   3. Install a new washer.

3. INSTALL GENERATOR COIL ASSEMBLY

   
   
   1. 

      *a	21 mm Deep Socket Wrench

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

   2. Install the 4 bolts.

      Torque:

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

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   
   
   1. 

      *a

      Pin

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

   2. 

      *a

      Pin

      Install the generator brush holder assembly to the generator coil assembly 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 assembly hole.

5. INSTALL GENERATOR REAR END COVER

   
   

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

      Torque:

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

6. INSTALL GENERATOR TERMINAL INSULATOR

   
   

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

      Note

      Make sure that the generator terminal insulator is installed with the correct orientation.

7. INSTALL GENERATOR PULLEY WITH CLUTCH

   
   

   1. Secure the generator drive end frame in a vise between aluminum plates.

   2. Temporarily install the generator pulley with clutch to the rotor shaft.

   3. 

      *a	Generator Rotor Shaft

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

      SST

      09820-63021

      Note

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

   4. 

      *a	Hold
      *b	Turn
      *c	Torque Wrench Fulcrum Length
      *d	SST Fulcrum Length

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

      Torque:

      Specified tightening torque

      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note

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

      Tech Tips

      
      

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.7 in.)):

        64 N*m (653 kgf*cm, 47 ft.*lbf)

   5. Remove SST from the generator assembly.

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

8. INSTALL GENERATOR PULLEY CAP

   
   

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