Generator Disassembly

Remove "B" terminal inner nut (3) and insulator (2).
Remove rear end cover (1).

Fig 1: Removing Rear End Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 screws (3) and pull out brush holder assembly (4).
Remove 3 screws (1) and IC regulator (2).
Remove brush holder cover from brush holder.

Fig 2: Removing 3 Screws And IC Regulator
Courtesy of SUZUKI OF AMERICA CORP.
Remove 4 screws, 1 bolt and rectifier (1).

Fig 3: Removing 4 Screws, 1 Bolt And Rectifier
Courtesy of SUZUKI OF AMERICA CORP.
Remove 4 rubber insulators (1).

Fig 4: Removing 4 Rubber Insulators
Courtesy of SUZUKI OF AMERICA CORP.
Hold shaft by using hexagonal box wrench (2) and remove pulley nut, and then pull out pulley (1).
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.
Fig 5: Holding Shaft By Using Hexagonal Box Wrench And Removing Pulley Nut
Courtesy of SUZUKI OF AMERICA CORP.
Remove 4 rear end frame nuts (3).
Drive out rear end frame (1) with tapping rotor shaft (2) lightly by using plastic hammer (4).
Separate rear end frame (1) from rotor evenly by using plastic hammer (4).
CAUTION: Do not hit shaft at slip ring side, when separating rotor and rear end frame.

Fig 6: Driving Out Rear End Frame With Tapping Rotor Shaft
Courtesy of SUZUKI OF AMERICA CORP.
If required, use bearing puller (2) to remove end housing bearing (1) and bearing cover (3).
CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller.

Fig 7: Removing End Housing Bearing And Bearing Cover
Courtesy of SUZUKI OF AMERICA CORP.
If required, remove 4 screws, retainer plate (2) and then drive out drive end bearing (3).
If required, remove stud bolts (1) and then pull out stator (4).

NOTE: Heating drive end frame may facilitate removal of stator.

Fig 8: Removing Stud Bolts (1) And Then Pull Out Stator

Courtesy of SUZUKI OF AMERICA CORP.