Generator Disassembly and Reassembly: Reassembly

Reference: GENERATOR DISASSEMBLY AND REASSEMBLY 

Reverse disassembly procedure for reassembly noting the following.

• Tighten each bolt, nut, screw and pulley (CVT model) to specified torque referring to GENERATOR COMPONENTS .
• Be sure to install brushes (1) in the proper direction as shown and solder brush wires (2) and stator leads (3).
Fig 1: Installing Brushes
Courtesy of SUZUKI OF AMERICA CORP.
• Install drive end bearing to drive end frame (1) using special tool and hydraulic press (2).

  Special Tool 

  (A): 09913-76010 

  Fig 2: Installing Drive End Bearing To Drive End Frame Using Special Tool And Hydraulic Press

  Courtesy of SUZUKI OF AMERICA CORP.
• Push brushes into brush holder, then support brushes by inserting appropriate wire (1) before installing IC regulator assembly (2) to rear end frame (3).
  NOTE: After installing rotor, remove wire.
  Fig 3: Identifying IC Regulator Assembly And Rear End Frame

  Courtesy of SUZUKI OF AMERICA CORP.
• Heat bearing box part (1) of rear end frame (2) to a temperature of 50 - 60 °C (122 - 140 °F) and install rear end bearing (3) with rotor into bearing box.
  CAUTION:

  • Be sure to install rear end bearing with bearing box heated. If not, it may cause damage to rear end bearing.
  • Do not apply grease to rear end bearing. Remove oil completely if found in bearing box of rear end frame.
  NOTE: Check that match marks on front and rear end frame are aligned.
  Fig 4: Installing Rear End Bearing With Rotor Into Bearing Box

  Courtesy of SUZUKI OF AMERICA CORP.
• After assembling generator, make sure that rotor turns smoothly.