Generator Disassembly

Remove the generator. Refer to "GENERATOR REMOVAL ".
Mark a match line that cannot easily be removed on the end frame to make assembly easier.
Pry off the plastic cover to expose the stator connections.

Fig 1: Removing Generator
Courtesy of SUZUKI OF AMERICA CORP.
Remove the stator connections from the rectifier bridge terminals by cutting the wires.
CAUTION: If the stator connections are not welded, melt the lead. Avoid excessive heating, as it can damage the diodes in the rectifier bridge.

Fig 2: Removing Stator Connections From Rectifier Bridge Terminals By Cutting Wires
Courtesy of SUZUKI OF AMERICA CORP.
Pry off the baffle.
Remove the rectifier/regulator/brush holder assembly screws.
Remove the brush holder assembly and the regulator.
NOTE: If the brush can be reused, reassemble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.

Fig 3: Removing Brush Holder Assembly And Regulator
Courtesy of SUZUKI OF AMERICA CORP.
Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.

Fig 4: Testing Rectifier Bridge By Connecting Ohmmeter Terminals To The Bridge And The Heat Sink
Courtesy of SUZUKI OF AMERICA CORP.
Retest by connecting the ohmmeter terminals in reverse.

Fig 5: Connecting Ohmmeter Terminals In Reverse
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Replace the rectifier bridge, if each reading is the same.
Test the remaining two diodes after the above procedure.
Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced.
NOTE: Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.

Fig 6: Testing Diodes
Courtesy of SUZUKI OF AMERICA CORP.
Remove the generator through - bolts.

Fig 7: Removing Generator Through - Bolts
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Move to the drive end of the generator and remove the drive end bearing nut.
NOTE: The fastening torque of this nut is 81 N.m (60 lb-ft) and may not normally be unfastened using hand strength.
Remove the pulley and the collars.

Fig 8: Removing Pulley And Collars
Courtesy of SUZUKI OF AMERICA CORP.
Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced.

Fig 9: Testing Rotor For Open Circuit
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Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be replaced.

Fig 10: Testing Rotor For Open And Short Circuits
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Remove the drive end frame from the shaft.
For vehicles with an internal generator fan, remove the drive end frame and the fan.

Fig 11: Removing Drive End Frame And Fan From Shaft
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Remove the rotor assembly.

Fig 12: Removing Rotor Assembly
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Remove the stator.

Fig 13: Removing Stator
Courtesy of SUZUKI OF AMERICA CORP.
Test the stator for an open circuit using the ohmmeter.

Fig 14: Testing Stator For Open Circuit Using Ohmmeter
Courtesy of SUZUKI OF AMERICA CORP.
Remove the ring in the slip ring end frame.

Fig 15: Removing Ring In Slip Ring End Frame
Courtesy of SUZUKI OF AMERICA CORP.