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Reassembly (80A/105A)

  1. If end housing bearing (1) is removed, install it.
  2. Check end housing bearing (1) turns smoothly. See Fig 1.
  3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
  4. If drive end bearing (3) is removed, install it.
  5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2). See Fig 2.
  6. Place drive end frame (2) on pulley, and install rotor (1) to drive end frame (2). See Fig 3.
  7. Install rear frame (1) to drive end frame (2). See Fig 4.
  8. Tighten 4 nuts to the specifications. See TORQUE SPECIFICATIONS .
  9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to the specifications. See Figure.
  10. Install 4 rubber insulators (1). See Figure.
    11. CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.
  11. Install rectifier (1). See Figure.
  12. Install brush holder cover (1) to brush holder (2). See Fig 5.
  13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
  14. Install the 5 screws until there is a clearance of approximately .04" (1 mm) between the brush holder (2) and connector. See Fig 6.
  15. Install rear end cover (1) and terminal plate (4).
  16. Install insulator (2) and tighten "B" terminal inner nut (3) to the specified torque. See TORQUE SPECIFICATIONS . See Fig 7.
  17. Ensure that rotor turns smoothly. See Fig 8.
Fig 1: Checking End Housing Bearing Position
G00305553Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Installing Drive End Bearing Retaining Plate
G00305554Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Installing Rotor To Drive End Frame
G00305555Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Installing Rear End Frame to Drive End Frame
G00305556Courtesy of SUZUKI OF AMERICA CORP.
Fig 5: Installing Brush Holder Cover To Brush Holder
G00305557Courtesy of SUZUKI OF AMERICA CORP.
Fig 6: Installing 5 Screws Between The Brush Holder
G00305558Courtesy of SUZUKI OF AMERICA CORP.
Fig 7: Installing Insulator
G00305559Courtesy of SUZUKI OF AMERICA CORP.
Fig 8: Checking Rotor Rotation
G00305560Courtesy of SUZUKI OF AMERICA CORP.
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