GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. A004IVB

      Install the generator holder with rectifier with the 3 bolts.

    2. A004IK8

      Install the terminal with the nut.

      Torque:
      8.9 N*m  { 91 kgf*cm, 79 in.*lbf }
    3. A004KXH

      Install the terminal cover.

  2. INSTALL BRUSH


    1. A004JNQE03
      Text in Illustration
      *1 Soldering iron
      *2 Solder

      Using a soldering iron, install the 2 brushes to the brush holder assembly.

    2. A004JNM

      Install the cover B to the brush holder assembly.

    3. A004I74

      Install the cover A to the brush holder assembly.

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A004J8UE01

      Install the generator brush holder assembly with the 4 bolts.

      Torque:
      Bolt A
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
      Bolt B
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf }
    2. A004JYKE02
      Text in Illustration
      *1 Pin 1.0 mm (0.0394 in.)

      While pushing the 2 brushes into the generator rear end cover, insert a 1.0 mm (0.0394 in.) pin into the generator rear end cover.

      Note

      Remove the pin after reassembling the generator.

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. A004IK5

      Install the generator coil assembly with the 6 bolts.

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

  5. INSTALL GENERATOR ROTOR BEARING


    1. A004K11

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

      SST
      09632-36010
      09820-36010

  6. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A004KISE02

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. A004I2C

      Install the bearing retainer with the 4 screws.

      Torque:
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf }

  7. INSTALL GENERATOR DRIVE END FRAME ASSEMBLY


    1. A004IU3

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

  8. INSTALL GENERATOR PULLEY


    1. A004HISE01
      Text in Illustration
      *1 Aluminium plate

      Mount the generator in a vise between aluminum plates.

    2. A004H92

      Install the generator pulley with the nut.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf }

  9. INSTALL GENERATOR REAR END COVER


    1. A004JDME01
      Text in Illustration
      *1 Heat gun

      using the heat gun, heat the generator rear end cover.

      Heating Temperature
      Item Temperature
      Generator Rear End Cover 50 to 60°C (122 to 140°F)

    2. Install the generator rear end cover.

    3. Pull out the pin of the generator rear end cover.

    4. A004JKA

      Install the 4 through bolts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }