Generator Replacement

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative (-) battery cable.

CAUTION: Failure to observe Step 1 may result in a serious personal injury. If a tool is shorted at the generator lead, the tool will become hot enough to cause a serious burn.

2. Remove the air cleaner assembly.
3 . Remove the rubber protector, the nut and the electrical connector from the generator B terminal.
4. Remove the upper mounting bolt (1).
5. Remove the drive belt.
6. Remove the 2 lower generator mounting bolts (2).
7. Remove the generator.

INSTALLATION PROCEDURE



1. Install the generator.
2. Install the lower mounting bolts (2) finger-tight.
3. Install the upper mounting bolt (1) finger-tight.




4. Install the drive belt.
^ Adjust the drive belt to obtain a 6-8 mm (0.24-0.31 in) deflection with 10 kg (22 lbs) pressure exerted when installing a used belt. Adjust the drive belt to obtain a 5-7 mm (0.20-0.27 in) deflection with 10 kg (22 lbs) pressure exerted when installing a new belt.
5. Tighten the generator upper mounting bolt.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten
Tighten the generator upper mounting bolt to 23 N.m (17 lb ft).

6. Tighten the generator lower mounting bolts.

Tighten
Tighten the generator lower mounting bolts to 23 N.m (17 lb ft).

7. Connect the electrical connector to the generator B terminal. Secure the connector with one nut and the rubber protector.

Tighten
Tighten the electrical connector nut to 8 N.m (71 lb in).

8. Install the air cleaner assembly.
9. Connect the negative (-) battery cable.

Tighten
Tighten the negative (-) battery cable-to-negative (-) battery terminal to 15 N.m (11 lb in).