GENERATOR (for 100 A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01IOHNE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )

    2. Install the retainer plate with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A01ITHY

      Place the generator drive end frame on the generator pulley.

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

    3. A01ITQ5E01
      Text in Illustration
      *1 Cutout
      *a Bearing Side

      Place a new washer on the rotor.

      Note

      Make sure that the cutout of the washer is oriented facing bearing.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01ISOZ

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

    2. Install the coil with the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01IO2JE01
      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. A01IRVLE01
      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 out the pin from the generator brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. Install the generator terminal insulator to the generator coil assembly.

  6. INSTALL GENERATOR REAR END COVER


    1. Install the rear end cover with the 3 bolts.

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

  7. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Temporarily install the generator pulley.

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

    3. A01IR6PE02

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

      SST
      09820-63021

      Note

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

    4. A01INSYE04
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      A01ISM9 Turn

      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

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

      Tech Tips


      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

    5. Check that the generator pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. A01INPH

      Install a new generator pulley cap.