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HOMESERVICE MANUALSSUZUKI2005VERONA EXREPAIR AND DIAGNOSISELECTRICALCHARGING SYSTEMSCHARGING SYSTEMREPAIR INSTRUCTIONSGENERATOR ASSEMBLY
2005 Suzuki Verona EX

Generator Assembly

2005 Suzuki Verona EXSECTION Generator Assembly
  1. Install the new ring in the slip ring end frame.
  2. Install the stator.
    Fig 1: Installing Stator
    G04094938Courtesy of SUZUKI OF AMERICA CORP.
  3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 inch).
  4. Install the generator through-bolts.

    Tighten 

    Tighten the generator through-bolts to 10 N.m (89 lb-in).

    Fig 2: Installing Generator Through-Bolts
    G04094939Courtesy of SUZUKI OF AMERICA CORP.
  5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.

    Tighten 

    Tighten the generator drive end bearing nut to 81 N.m (60 lb-ft).

    Fig 3: Tightening Generator Drive End Bearing Nut
    G04094940Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the generator. Refer to "GENERATOR INSTALLATION "
  7. Weld the brush holder terminal to the regulator terminal, if removed.
  8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
  9. Apply silicone grease between the bridge and the end frame for radiation purposes.
  10. Fasten the screws holding the rectifier regulator/ brush holder assembly to the end frame.
  11. Punch the new baffle with the pin into the brush.
    Fig 4: Punching New Baffle With Pin Into Brush
    G04094941Courtesy of SUZUKI OF AMERICA CORP.
  12. Weld the connectors of the rectifier bridge.
    CAUTION: Take care to prevent damage to the vehicle by protecting the diode in the rectifier bridge from excessive heat while welding.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.