Alternator & Regulator: Overhaul: Sidekick: Reassembly

1. Install new bearings on either rotor or front drive housing (if required) using a hydraulic press. Install alternator pulley. Tighten pulley nut to 44-51 ft. lbs. (60-70 N.m).
2. Solder brushes to regulator in proper direction. See Fig 1. Install new brush springs. Install brushes into brush holder and slide appropriate sized piece of wire through holes in brush holder to retain brushes. Install brush holder so that wire protrudes through rear of alternator case.
3. Ensure that stator terminal insulation is properly installed and install stator. Heat rear bearing as in step 1) and assemble alternator halves, making sure to align scribe marks.

CAUTION: Ensure wire that retains brushes is removed before reconnecting negative battery cable.

Fig 1: Identifying Alternator Brushes (Sidekick)

Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Exploded View of Alternator (Samurai & Swift)

Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Exploded View of Alternator (Sidekick)

Courtesy of SUZUKI OF AMERICA CORP.