Starting/Charging Systems (H4SO): Generator: Assembly

Assemble in the reverse order of disassembly.

1. Pull-out of the brush

   Before assembling, press the brush down into the brush holder, then fix the brush in that position by inserting a [1 mm (0.08 in) dia., 40 to 50 mm (1.6 to 2.0 in) long] wire through the hole as shown in the figure.

   CAUTION: After re-assembling, remove the wire.
   Fig 1: Inserting Wire Through Hole

   
2. Install the ball bearings.
   1. Set the ball bearings in the front cover, then securely install an appropriate tool (such as a socket wrench of proper size) to the bearing outer race.
   2. Using a press to press the ball bearings into the specified location.
   3. Install the bearing retainer.
3. Use a press to install the bearings (rear side) to the rotor shaft.
4. Heat the bearing box in rear cover [50 to 60°C (122 to 140°F)], and then press the rear bearing into rear cover.
   CAUTION: Do not apply grease to the rear bearings. If there is any oil on the bearing box, remove it completely.
5. After re-assembling, manually turn the pulley to check that the rotor rotates smoothly.