Generator Disassembly and Reassembly: 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 in figure and solder brush wires (2) and stator leads (3).

Fig 1: Installing Brushes

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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
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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
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Install rear end bearing (3) as the following steps.
1. Degrease inner of bearing box part (1) of rear end frame (2) and outer of rear end bearing.
2. Heat bearing box part of rear end frame to a temperature of 50 - 60 °C (122 - 144 °F).
3. Install rear end bearing with rotor into bearing box part of rear end frame.
CAUTION: If the rear end bearing is press-fitted into the bearing box that is not heated, the bearing could be damaged. Be sure to heat the bearing box to the specified temperature before press-fitting the rear end bearing.

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.