GENERATOR (for 100A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A011880E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01173CE01
      Text in Illustration
      *a Tab
      *b 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. Place the drive end frame on the clutch pulley.

    2. A01172Y

      Install the generator rotor assembly onto the drive end frame.

    3. A01182IE01

      Place the generator washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A0119I5E01

      Using SST and a press, slowly press in the generator coil assembly.

      SST
      09612-70100   ( 09612-07240 )
    2. A011AEI

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A011734E10
      Text in Illustration
      *1 Pin (φ1.0 mm)

      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. A0118A4

      Install the brush holder assembly onto the generator coil with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A011980

      Pull out the pin from the generator brush holder.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A011ATW

      Install the terminal insulator onto the generator coil.

      Note

      Pay attention to installation direction of the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A0118ZI

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

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

  7. INSTALL GENERATOR CLUTCH PULLEY


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

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

    3. A0117H5E02

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

      SST
      09820-63021
    4. A0118B4E01
      Text in Illustration
      *1 Rotor Shaft

      Place the rotor shaft end into SST (A).

    5. A011BM7E01
      Text in Illustration
      *1 Clutch Pulley

      Fit SST (B) to the clutch pulley.

    6. A0117F1E01
      Text in Illustration
      *a Hold
      *b Length 100 mm
      *c Length 318 mm
      *d Turn

      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
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

      Note


      • Check that the drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).

      • This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

    7. Remove the generator assembly from SST.

    8. Check that the clutch pulley rotates smoothly.

    9. Install a new generator pulley cap onto the clutch pulley.