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Diassembly (80A/105A)

  1. Remove "B" terminal inner nut "3" and insulator "2".
  2. Remove rear end cover "1". See Fig 1 .
  3. Remove 2 screws "3" and pull out brush holder assembly "4".
  4. Remove 3 screws "1" and IC regulator "2".
  5. Remove brush holder cover from brush holder. See Fig 2 .
  6. Remove 4 screws, 1 bolt and rectifier "1". See Fig 3 .
  7. Remove 4 rubber insulators "1". See Fig 4 .
    8. CAUTION: To hold shaft, use hexagonal box. Duodecimal box may cause slipping and consequential shaft or tool damage. Do not attempt to hold pulley by using vise or pipe wrench so as not to distort it.
  8. Hold shaft by using hexagonal box wrench "2" and remove pulley nut, and pull out pulley "1". See Fig 5 .
  9. Remove 4 rear end frame nuts "3".
  10. Drive out rear end frame "1" with tapping rotor shaft "2" lightly by using plastic hammer "4".
    11. CAUTION: Do not hit shaft at slip ring side, when separating rotor and rear end frame.
  11. Separate rear end frame "1" from rotor evenly by using plastic hammer "4". See Fig 6 .
    12. CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller.
  12. If required, use bearing puller "2" to remove end housing bearing "1" and bearing cover "3". See Fig 7 .
  13. If required, remove 4 screws, retainer plate "2" and drive out drive end bearing "3".
    14. NOTE: Heating drive end frame may facilitate removal of stator.
  14. If required, remove stud bolts "1" and then pull out stator "4". See Figure .
Fig 1: Removing Rear End Cover
G00305542Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Removing Brush Holder Cover From Brush Holder
G00305543Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Removing Rectifier
G00305544Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Removing 4 Rubber Insulators
G00305545Courtesy of SUZUKI OF AMERICA CORP.
Fig 5: Removing Pulley Nut
G00305546Courtesy of SUZUKI OF AMERICA CORP.
Fig 6: Removing Rear End Frame From Rotor
G00305547Courtesy of SUZUKI OF AMERICA CORP.
Fig 7: Removing End Housing Bearing And Bearing Cover
G00305548Courtesy of SUZUKI OF AMERICA CORP.
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