Alternator & Regulator: Overhaul: Reassembly

1. Install NEW bearings on rotor and front drive housing using a hydraulic press. Install alternator pulley. Tighten pulley nut to 43.5-50.5 ft. lbs. (60-70 N.m).
2. Solder brushes to regulator in proper direction. Refer to Fig 1. Install NEW brush springs. Install brushes into brush holder, support brushes with appropriate sized wire inserted through hole in rear of housing. Install brush holder so that wire protrudes through rear of alternator case.
3. Ensure stator terminal insulation is properly installed and install stator. Heat rear bearing as in step 1) and assemble alternator halves, ensuring scribe mark alignment. After assembling alternator, ensure rotor turns freely.

CAUTION: Before reconnecting negative battery cable, ensure wire retaining brushes is removed.

Fig 1: Identifying Alternator Brushes

Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Exploded View Of Alternator (Typical)

Courtesy of SUZUKI OF AMERICA CORP.