GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A019L1FE01

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. A019KWZ

      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. A019LNZ

      Place the generator drive end frame on the generator pulley.

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

    3. A019PF4E01

      Place the washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A019ONKE02
      Text in Illustration
      *1 21 mm Socket Wrench

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

    2. A019LAI

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A019OKKE18
      Text in Illustration
      *1 Pin

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

    2. A019L0TE02
      Text in Illustration
      *1 Pin

      Install the generator brush holder with the 2 screws.

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

    3. Pull the pin out of the generator brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A019N8R

      Install the terminal insulator onto the generator coil assembly.

  6. INSTALL GENERATOR REAR END COVER


    1. A019KWW

      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 WITH CLUTCH


    1. A019OZBE04
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021

    2. Temporarily install the generator pulley by hand.

    3. Mount the generator in a vise.

    4. A019KODE02
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

    5. A019NKIE05
      Text in Illustration
      *1 SST (A)
      *2 SST (B)
      *a Fulcrum Length: 400 mm

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


      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 400 mm (1.312 ft.).

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

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

      • Hold SST (A) tightly during the operation.

    6. Check that the generator pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. A019KL4

      Install a new generator pulley cap to the pulley.