Generator Disassembly And Assembly: Assembly

Reference: GENERATOR INSPECTION .

Reference: GENERATOR COMPONENTS .

1. Install rectifier (4) to rear housing and then tighten screw (3).
2. Install regulator assembly (2) to rear housing and then tighten screw (1).
   Fig 1: Identifying Rectifier & Regulator Assembly

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3. Install insulator (2) and then tighten "B" terminal nut to specified torque.

   Tightening torque 

   "B" terminal nut: 9 N.m (0.9 kg-m, 7.0 lb-ft) 

4. Install cap (1) to insulator (2).
   Fig 2: Identifying Cap & Insulator

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5. Depress brush and then while holding it depressed, and insert pin (1) to hole of rear housing (2).
   Fig 3: Identifying Pin

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6. Install stator (2) to rear housing by aligning match marks provided before removal and then tighten screw (1).
   Fig 4: Identifying Stator

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7. If rear end bearing (2) is removed, install it by using hydraulic press (1).
   Fig 5: Installing Rear End Bearing Using Hydraulic Press

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8. If drive end bearing is removed, install it.
   1. Press-fit drive end bearing by using hydraulic press (1) and special tool.

      Special Tool 

      1. 09913-76010 
         Fig 6: Installing Drive End Bearing Using Hydraulic Press & Special Tool

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   2. Install retainer and then tighten retainer screw (1).
      Fig 7: Identifying Retainer Screw

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9. Insert stator to front housing and install pulley and pulley nut.
10. Hold rotor by using vise (1) and tighten pulley nut to specified torque.
    CAUTION: When using vise, put clean cloth (2) and aluminum plate (3) between rotor (4) and vise (1) so as not to cause damage to rotor.

    Tightening torque 

    Pulley nut: 118 N.m (11.8 kg-m, 85.5 lb-ft) 

    Fig 8: Tightening Pulley Nut

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11. Install front housing with rotor (1) to stator (2) by aligning match marks provided before removal and then tighten frame bolt (3) to specified torque.

    Tightening torque 

    Frame bolt a: 4 N.m (0.4 kg-m, 3.0 lb-ft) 

    Fig 9: Installing Front Housing With Rotor To Stator

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12. Remove pin (1) from rear housing (2).
    Fig 10: Identifying Pin

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13. Make sure that rotor turns smoothly.