Generator (For 100 A Type) Reassembly

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

SST

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

Fit the tabs on the retainer plate into the cutouts on the generator drive end frame to install the retainer plate.

Install the 4 screws.

Torque:

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

Install the generator rotor to the generator drive end frame.

Place a new generator washer on the generator rotor.

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

Install the 4 bolts.

Torque:

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

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

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

Torque:

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

Pull out the pin from the brush holder.

Install the terminal insulator to the generator coil.

NOTICE:

Make sure the terminal insulator is installed facing the proper direction.

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

Torque:

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

Install the cord clip with the nut.

Torque:

6.2 N*m{63 kgf*cm, 55 in.*lbf}

Temporarily install the generator pulley with clutch by hand.

Mount the generator in a vise between aluminum plates.

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

SST

09820-63021

NOTICE:

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

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

Torque:

without SST:

80 N*m{816 kgf*cm, 59 ft.*lbf}

with SST:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Text in Illustration

*1	Fulcrum Length
*a	Hold
	Turn

NOTICE:

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.

HINT:

1. 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).
   
2. Make sure SST and the wrench are connected in a straight line.
   

Remove SST from the generator.

Check that the generator pulley with clutch rotates smoothly.

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