Starting/Charging (H4SO): Generator: Assembly

Assemble in the reverse order of disassembly.

1. Pull-out of the brush

   Before assembling, push the brush into the brush holder. Then pass a wire through the hole (dia. 1 mm (0.0394 in), Length: 4 to 5 cm (1.6 to 2.0 in) and fasten at that position.

   CAUTION: After re-assembling, remove the wire.
   Fig 1: Identifying Wire

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