GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR BEARING


    1. A01FILVE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01FHDGE01
      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. Place the drive end frame on the generator pulley with clutch.

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

    3. Place a new generator washer on the generator rotor.

  3. INSTALL GENERATOR PULLEY WITH CLUTCH


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

    2. Mount the drive end frame in a vise tightly.

    3. A01FE8WE03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021
    4. A01FE1XE02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. A01FIZ6E02
      Text in Illustration
      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)

      Fit SST (B) to the generator pulley with clutch.

    6. A01FGBZE03
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *3 Fulcrum Length

      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
      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 the torque wrench.

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

      • Hold SST (A) tightly during the operation.

    7. Remove SST from the generator assembly.

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

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

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. A01FE01E05
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

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

    2. Install the 4 bolts.

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

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01FFHRE18
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the brush holder, insert a 1.0 mm (0.0394 in.) diameter pin into the brush holder hole.

    2. A01FDHME05
      Text in Illustration
      *1 Pin

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

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

    3. Pull out the pin from the brush holder.

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. Install the terminal insulator to the generator coil.

      Note

      Pay attention to the installation direction of the terminal insulator.

  7. INSTALL GENERATOR REAR END COVER


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

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