Generator, Starter and Pick-up Coil Reassembly

Submitted by xjcdadmin on Thu, 04/23/2009 - 15:15

8. A.C. Generator

a. Install the rotor onto the shaft and tighten the bolt using the rotor holding tool (special tool) as shown.

1. Rotor holding tool

Tightening torque: 5.5 m-kg (39.8 ft-lb)

b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.

c. Install the A.C.G. cover assembly and tighten the bolts to the specification. Do not forget to install the new gasket.

Tightening torque: 1.0 m-kg (7.2 ft-lb)

9. Starter motor

a.   Route the A.C.G. lead wires as shown.

b.   Install the starter motor and tighten the bolts to the specification.

Tightening torque: 1.2 m-kg (8.7 ft-lb)


Be careful the "O-ring" is not damaged when installing the starter motor.

1. O-ring    2. A.C.G. lead wires

10. Pick-up coil assembly

a.   Install the pick-up coil assembly onto the crankcase.

b.   Install the timing plate on the crankshaft and tighten the bolt to the specification.


Note that there is the locating pin on the crankshaft and the corresponding slot in the timing plate which must be aligned to install the timing plate.