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Home >> Suzuki >> 2005 >> XL-7 LX, 4WD, Standard >> Repair and Diagnosis >> Electrical >> Charging Systems >> Charging System >> Repair Instructions >> Generator Reassembly
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Generator Reassembly

  1. If end housing bearing (1) is removed, install it.
  2. Check end housing bearing (1) turns smoothly.
    Fig 1: Checking End Housing Bearing Turns Smoothly
    G04098287Courtesy of SUZUKI OF AMERICA CORP.
  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).

    Tightening torque 

    Stator stud bolt (a): 8.8 N.m (0.88 kg-m, 6.5 lb-ft) 

    Drive end bearing retaining plate screw (b): 2.6 N.m (0.26 kg-m, 2.0 lb-ft) 

    Fig 2: Installing Drive End Bearing Retaining Plate
    G04098288Courtesy of SUZUKI OF AMERICA CORP.
  6. Place drive end frame (2) on pulley, and then install rotor (1) to drive end frame (2).
    Fig 3: Installing Rotor To Drive End Frame
    G04098289Courtesy of SUZUKI OF AMERICA CORP.
  7. Install rear end frame (1) to drive end frame (2).
  8. Tighten 4 nuts to specified torque.

    Tightening torque 

    Rear end frame nut (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 

    Fig 4: Installing Rear End Frame To Drive End Frame
    G04098290Courtesy of SUZUKI OF AMERICA CORP.
  9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to specified torque.

    Tightening torque 

    Generator pulley nut (a): 111 N.m (11.1 kg-m, 80.5 lb-ft) 

    Fig 5: Installing Pulley And Tightening Pulley Nut With Holding Shaft
    G04098291Courtesy of SUZUKI OF AMERICA CORP.
  10. Install 4 rubber insulators (1).
    Fig 6: Install 4 Rubber Insulators
    G04098292Courtesy of SUZUKI OF AMERICA CORP.
  11. Install rectifier (1).
    CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.

    Tightening torque 

    Rectifier screw (a): 2 N.m (0.2 kg-m, 1.5 lb-ft) 

    Rectifier "B" bolt (b): 3.9 N.m (0.39 kg-m, 3.0 lb-ft) 

    Fig 7: Installing Rectifier
    G04098293Courtesy of SUZUKI OF AMERICA CORP.
  12. Install brush holder cover (1) to brush holder (2).
    Fig 8: Installing Brush Holder Cover To Brush Holder
    G04098294Courtesy of SUZUKI OF AMERICA CORP.
  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 "a" of approx. 1 mm (0.04 in.) between the brush holder (2) and connector.

    Tightening torque 

    Regulator and brash holder screw (a): 2 N.m (0.2 kg-m, 1.5 lb-ft) 

    Clearance between the brush holder and connector 

    "a": 1 mm (0.04 in.) 

    Fig 9: Measuring Clearance Between Brush Holder And Connector
    G04098295Courtesy of SUZUKI OF AMERICA CORP.
  15. Install rear end cover (1) and terminal plate (4).

    Tightening torque 

    Rear end cover nut (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 

    Terminal plate bolt (b): 3.8 N.m (0.38 kg-m, 3.0 lb-ft) 

  16. Install insulator (2) and tighten "B" terminal inner nut (3) to specified torque.

    Tightening torque 

    "B" terminal inner nut (c): 8 N.m (0.8 kg-m, 6.0 lb-ft) 

    Fig 10: Installing Insulator And Tightening "B" Terminal Inner Nut To Specified Torque
    G04098296Courtesy of SUZUKI OF AMERICA CORP.
  17. Make sure that rotor turns smoothly.
    Fig 11: Make Sure That Rotor Turns Smoothly
    G04098297Courtesy of SUZUKI OF AMERICA CORP.
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