GENERATOR REASSEMBLY

PROCEDURE

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, install a new generator drive end frame bearing.
  
  SST
  
  09950-60010 ( 09951-00470 )
  
  09950-70010 ( 09951-07100 )
2. *a Tab
  
  *b Cutout
  
  Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
3. Install the 4 screws.
  
  Torque:
  
  2.95 N*m { 30 kgf*cm, 26 in.*lbf }
INSTALL GENERATOR ROTOR ASSEMBLY
1. *1 Generator Rotor Assembly
  
  *2 Generator Drive End Frame
  
  Install the generator rotor assembly to the generator drive end frame.
2. *a Cutout
  
  Place a new washer on the generator rotor assembly.
  
  Note
  
  Make sure to install the washer so that its cutout faces the bearing side, as the washer must be installed in a specific direction.
INSTALL GENERATOR COIL ASSEMBLY
1. Temporarily install the generator coil assembly to the generator drive end frame with the 4 through bolts.
  
  Note
  
  Because the generator coil assembly must be installed with a press after the through bolts have first been temporarily tightened, do not attempt to install the generator coil assembly by tightening the through bolts only.
2. Using SST and a press, slowly install in the generator coil assembly.
  
  SST
  
  09612-70100 ( 09612-07240 )
3. Place the generator assembly on the generator pulley with clutch.
4. Tighten the 4 through bolts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. *a Pin (1.0 mm)
  
  While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.
2. *a Pin (1.0 mm)
  
  Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
  
  Torque:
  
  1.76 N*m { 18 kgf*cm, 16 in.*lbf }
3. Pull out the pin from the generator brush holder assembly.
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the generator terminal insulator to the generator coil assembly.
  
  Note
  
  Be sure to install the generator terminal insulator in the correct orientation.
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.
  
  Torque:
  
  4.55 N*m { 46 kgf*cm, 40 in.*lbf }

INSTALL GENERATOR PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.

Note

Do not overtighten the vise.
Temporarily install the generator pulley with clutch to the generator rotor shaft.
*a Generator Rotor Shaft

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

SST

09820-63021

Note

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

*a	Torque Wrench Fulcrum Length
*b	SST Fulcrum Length
*c	Hold
	Turn

Using a wrench to hold SST A and turn SST B clockwise to tighten the generator pulley with clutch.

Torque:: Specified tightening torque; 80 N*m { 816 kgf*cm, 59 ft.*lbf }

Note

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

Tech Tips

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click here
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

Remove SST from the generator assembly.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator drive end frame from the vise.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.

*a	Tab
*b	Cutout

*1	Generator Rotor Assembly
*2	Generator Drive End Frame