GENERATOR (for 100 A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A00OVFFE01

      Using SST and a press, press in a new bearing.

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

    2. Install the retainer plate with the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A00OT3M

      Place the generator drive end frame on the generator pulley.

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

    3. Place a new washer on the rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A00OSR5

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

    2. Install the coil with the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A00OT9WE01
      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. A00OQV6E01
      Text in Illustration
      *1 Pin

      Install the generator brush holder 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. Install the generator terminal insulator to the generator coil assembly.

  6. INSTALL GENERATOR REAR END COVER


    1. Install the rear end cover with the 3 bolts.

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

  7. INSTALL GENERATOR PULLEY


    1. Temporarily install the generator pulley.

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

    3. A00OV8TE02

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

      SST
      09820-63021

      Note

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

    4. A00OTVWE04
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      A00OV9Z Turn

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

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

      Note


      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.).

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

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

    5. Check that the generator pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. A00OTHX

      Install a new generator pulley cap.