GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR BEARING


    1. A00DSAVE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A00DUN5E03
      Text in Illustration
      *1 Tab
      *2 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. A00DTSJ

      Place the drive end frame on the generator with clutch pulley.

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

    3. A00DTOM

      Install the washer to the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A00DRTIE06
      Text in Illustration
      *1 21 mm Deep Socket Wrench

      Using a 21 mm deep socket wrench and a press, slowly press on the generator coil to install it.

    2. A00DR8N

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A00DV4AE09
      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. A00DUNA

      Install the generator brush holder to the generator coil with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A00DS70

      Pull out the pin from the generator brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A00DQ1A

      Install the terminal insulator to the generator coil.

      Note

      Pay attention to the installation direction of the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A00DQQK

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

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

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. A00DT3ME01
      Text in Illustration
      *1 Rotor Shaft

      Temporarily install the generator with clutch pulley by hand.

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

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

      SST
      09820-63021

      Note

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

    4. A00DUNZE04
      Text in Illustration
      *1 Hold
      *2 Turn

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


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

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

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

    5. Remove SST from the generator.

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

  8. INSTALL GENERATOR PULLEY CAP


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