Alternator & Regulator: Overhaul: Reassembly

To reassemble, reverse disassembly procedure. Install NEW bearings on rotor and front housing using a hydraulic press.
Ensure stator terminal insulation is properly installed. Install alternator pulley. Tighten pulley nut to 37-47 ft. lbs. (50-65 N.m). After assembling alternator, ensure rotor turns freely.

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

Fig 1: Identifying Alternator Brushes (Typical)

Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Exploded View Of Alternator (Typical)

Courtesy of SUZUKI OF AMERICA CORP.