GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Install the generator rotor.

    2. Install the generator washer onto the rotor.

  2. INSTALL GENERATOR RECTIFIER END FRAME

    A01J6XKE01

    1. Using a 19 mm socket wrench and press, slowly press in the rectifier end frame.

    2. Install the 4 nuts.

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

    3. Install the seal plate onto the rectifier end frame.

    4. A01J7BIE01

      Install the 3 rubber insulators onto the lead wires.

      Note

      Be careful that the rubber insulators are in the right direction.

  3. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. Install the rectifier holder while pushing it with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  4. INSTALL VOLTAGE REGULATOR ASSEMBLY


    1. Install the 3 screws and voltage regulator.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A01J7B8E01

    1. Install the brush holder with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

      Note

      Be sure to install the holder in the correct direction.

    2. Install the brush holder cover.

  6. INSTALL GENERATOR REAR END COVER


    1. A01J7AY

      Install the end cover and plate terminal with the bolt and 3 nuts.

      Torque:
      3.9 N*m  { 40 kgf*cm, 34 in.*lbf, for bolt }
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf, for nut }

    2. Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

  7. INSTALL GENERATOR PULLEY


    1. Temporarily install the generator pulley by hand.

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

    3. A01J6TIE01

      Install SST 1-A to the pulley shaft.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )

      Tech Tips

      SST 1-A and B 09820-06010
      SST 2 09820-06021

    4. Install SST 1-B to SST 1-A.

    5. Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Make sure that SST is secured to the rotor shaft.

    6. A01J4SQE02

      Insert SST 2 and attach it to the pulley nut.

    7. A01J6LAE01

      Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

      Torque:
      133 N*m  { 1356 kgf*cm, 98 ft.*lbf }

    8. Remove SST 2 from the generator.

    9. A01J712E01

      Turn SST 1-B in the direction shown in the illustration and remove SST 1-A and B.

    10. Turn the generator pulley and check that the generator pulley moves smoothly.