Generator Reassembly

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

SST

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

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

Install the 4 screws.

Torque:

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

Place the drive end frame on the generator pulley with clutch.

Install the generator rotor to the generator drive end frame.

Place the washer on the generator rotor.

Using a 21 mm deep socket wrench and a 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 generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

Install the generator 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 generator brush holder.

Install the generator terminal insulator to the generator coil.

NOTICE:

Pay attention to installation direction of the generator terminal insulator.

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

Torque:

4.6 N*m{47 kgf*cm, 41 in.*lbf}

Temporarily install the generator pulley with clutch by hand.

Mount generator in a vise between aluminum plates.

Install SST (A) and (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 generator 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}

NOTICE:

1. 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.
   
2. Use a torque wrench with a fulcrum length of 400 mm (15.7 in.).
   
3. This torque value is effective when SST is parallel to the torque wrench.
   

Remove the generator from SST.

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