GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01J6S0E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01J3Z3E01

      Align the claws of the bearing retainer with the grooves inside the drive end frame.

    3. Install the bearing retainer with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

      Note

      Do not drop the generator rotor.

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

    3. Install the washer to the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01J5IEE01

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

    2. A01J42T

      Install the generator coil assembly with the 4 through bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01J36DE01

      While pushing the 2 brushes inside the brush holder, insert a φ1.0 mm (0.039 in.) pin into the brush holder hole.

    2. A01J41ME01

      Install the brush holder with the 2 screws.

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

    3. Pull out the pin from the brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A01J65F

      Install the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A01J3OE

      Install the generator rear end cover with the 3 nuts.

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

  7. INSTALL GENERATOR PULLEY


    1. Install the pulley to the rotor shaft by tightening the generator pulley nut by hand.

    2. A01J3CJE06

      Install SST 1-A and B to the rotor shaft.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )
      Item Part No.
      SST 1-A and B 09820-06010
      SST 2 09820-06021

    3. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Make sure that the SST is secured to the rotor shaft.

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

    5. A01J4B9E01

      Insert SST 2 to attach it to the pulley nut.

    6. A01J3VTE01

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

      Torque:
      111 N*m  { 1127 kgf*cm, 81 ft.*lbf }

    7. Remove SST 2 from the generator.

    8. A01J3ZNE03

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

    9. Turn the pulley, and check that the pulley moves smoothly.