Vitesse said:

...The fact that the alternator is giving out a voltage suggests the voltage regulator on the alternator is faulty. I would try that first...

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I had thought that, but I'm still questioning my wiring. It'll be a couple days until I can get dig into it again, but perhaps I should order the regulator now since its cheap and I'll need another some day regardless.

While I'm at a productivity standstill (3 days of working 12 hour shifts), can anyone suggest a means of additional engine mounting? The smallest blip on the throttle jars it about 4-6cm, looks like it would launch itself out of the bay if I romped on it!

Well I took off the bit in the 3rd pic which exposed the alternator part number, but then I noticed that the female end is two-post and the male end is three-post. Tried to get a close pic to see the writing for what each post is, but I just can't make it out. I'm wondering if it's been connected wrong? Does anyone have a diagram for these?

Neighbor had the tool to get the brushes off, now I can see it. The outer two are connected to each other. So both outer posts are "D+" and the middle post is "DF" then.

Andrew; to set your mind at rest, I have just checked my spare alternator which has the same 'cast in base' number as yours. Although the 'female' multi-plug is just 2-posted for the 3 'male' pins in alternator, I think that you will find that, due to the shape of the plastic sheath on the 'female' multi-plug, it can only fit in one position---onto the 2 left-hand terminals (on the alternator) as you look at the brushes-end of the alternator.

The third terminal connects to the charge warning light. If the warning light isn't connected your circuit will be open and won't charge.

This might be useful:


https://www.fiat500club.org.uk/home/wiring-an-alternator/

Hutbed said:

Neighbor had the tool to get the brushes off, now I can see it. The outer two are connected to each other. So both outer posts are "D+" and the middle post is "DF" then.

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I think it's right to have just two connections out of that plug. This is a Marelli alternator on a 126 engine. Some, eg. my 900 van, do have three connections.

MOD500 said:

The third terminal connects to the charge warning light. If the warning light isn't connected your circuit will be open and won't charge.

This might be useful:


https://www.fiat500club.org.uk/home/wiring-an-alternator/

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Sorry I beg to differ, it will still charge it just won’t have a working warning light.

I must have got my wires crossed.

MOD500 said:

I must have got my wires crossed.

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'Boom-Tish'...…….he's here all night

FINALLY started posting my videos on YouTube. I'm doing a series on owning, driving, repairing, and resto-modding my 500. The video of my engine swap will be uploaded soon. Here's a link to the first in the series. If nothing else, you can laugh at me grinding into 1st a few times. Haha.

Admins: I read through the rules and determined this was ok to link since I'm not selling anything, I will gladly remove it if I am mistaken.

[ame]https://youtu.be/hn9c1ApanLw[/ame]

Neat video Andrew---look forward to edition 2 + 3+ ----! The hand-throttle must NOT be used as a simple form of cruise control. A 'proper' cruise control is disabled as soon as the throttle or brake is used---the hand-throttle on the Fiat, being that it is completely mechanical, does not dis-engage, which could (and probably would) lead to expensive and embarrassing consequences. It must ONLY be used as a device for warming the engine up when the 'choke' not being used,

Thank you Tom, and I actually have 5 episodes up already now. I've had videos waiting to be edited from the work over the past months. Making new videos now (much better quality, haha) so there are plenty more coming.

So I have now broken two shaft mounts, oddly one was the original and the second was the newly replaced one with original still in place on the other side. Found some talk of "Motomax tripod" replacements, but I wanted to ask- if I'm pushing roughly 50hp/tq, what would you do? Is there a stronger version I may be able to find in the junkyards here in Sicily for a quick and easy strength increase?

Hutbed said:

..........................................? Is there a stronger version I may be able to find in the junkyards here in Sicily for a quick and easy strength increase?

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stronger but not in junk yards...

https://www.bacciromano.com/en/products/products/vintage-car/fiat/500/?page=2

probably from the company in Germany who's name escapes me....

Bigvtwin996 said:

stronger but not in junk yards...

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Some impressive stuff there, but unfortunately a bit too pricey for me. Between the car, the new engine, and the sport suspension I'm still only about €3800 in on this car, hoping to keep that trend going if possible. I've also heard about welding shafts, but would like to avoid it for disassembly. Is there maybe a set of shafts that just goes the entire length? I'm about 90% sure I have a clutch disc with springs... **edit: found a pic of disassembly, I do NOT have clutch springs. Solid axles are a no I guess.**

Anyone using these from "Fiat500sport.com"?
Do these require a spring type clutch disc?

I am using those Tripod joints. Very well made and easy to install, they seem to take the power well allow more movement in the suspension without any strain.

They have been on the 500 about 20000miles now over the last 6 years, 4000miles with a 650 engine and the last 16000miles with a 803cc engine with 55hp.

Using a standard friction plate clutch, not sprung with no problems

I have a set of these 'tripod' couplings to fit when I fit my '695' engine. I didn't like the idea of fitting a 'nylock' nut on backwards (i.e. nylon insert first) so I have had a couple of little washers made that match the shape of the inside of the coupling and therefore allow the nylok nut to be fitted the correct way round. The reason that the nut has to be fitted backwards is so that the rounded part of the nut, where the nylon insert is, matches the shape of the coupling on the inside of the part that fits onto the stub-axle.