Bleeding Knuckles said:

The vid is great thanks I'll be using it as a blueprint -

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....it's very gratifying when the digits come up just as described, (or maybe not ). The only issue I had was that I couldn't see a fourth, common terminal from the stator coils as mine is still partly assembled (Marelli). But I got there eventually.

I had already ordered all the gubbins to change the internals regardless, but as I am now confident that it's all working, I'll have a good stock of spares against future problems.

fiat500 said:

....it's very gratifying when the digits come up just as described,

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Hi Peter, Yes, I agree when the numbers match the spiel it is gratifying indeed. I used the vid and tested the old and new rectifiers (diode plate) and guess what even the old grotty item passed so the new one becomes a spare I have for the future. However, getting the two halves of the case apart -sliding the rotor shaft out of the bearings is proving a tad difficult, I'm not changing the bearings as they are fine. I can test the stator as is, but I'd like to get a good look at the slip rings Too, are you having any problems???? My alternator is an Elmot by the way.
Ian.

Bleeding Knuckles said:

, are you having any problems???? .

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The one I'm working on is a Marelli, but I've previously done an Elmot too. Tony, Vitesse is your man, having recently been through all that with your type of alternator.

https://www.fiatforum.com/500-classic/462293-zelmot-alternator-pulley-hub-removal.html

The rotor should come out if you have a dead-blow hammer and can hold the casing in one hand whilst tapping the shaft with the hammer. If you can get a puller to grip evenly somewhere, you can push the shaft out.

I have a trick for cleaning up the slip-ring once it's out, I'll photograph tomorrow.

Once you have undone the three long bolts that hold the two parts together and removed the brushes. The casing on the fan side that has the bearing mounted inside it, should just pull off the rotor easily. It sounds like the rotor is stuck inside that bearing from your description?

As Peter said a little tapping on the pulley end of the rotor with a soft faced plastic hammer should knock the casings apart and the stator will stay with the main casing on the pulley side that has the mounting bracket on. It’s possible that the stator is stuck inside the fan side of the casing also but a little tapping should free it apart without doing any damage.

I had to provide a link to this small company, which has an amazing range of electrical components for the repair of alternators etc. They also stock complete units. Their website search engine is amazing as long as you have an accurate part number. The standard of personal service matches the quality of everything else.

I was able to get brushes, bearings, rectifier and control unit for less than half the price charged at Fiat specialists....highly recommended.

https://www.unistart.co.uk/

Greetings, Much going on behind the scenes with the Alternator so this thread has been a tad quiet, but no longer
I had got the point of destroying my unit trying to get it apart, but no, the damn thing would not come apart so I chickened out and sent it to Tom (@the hobbler) as he knows a man who can !!!!! One bearing and a second hand stator later it's back in my hands looking all shiny and bright (cue a warm fuzzy feeling) So I'm now back on with the reassembly. Thanks to Tom 'again' for the replacement fan and only 20 nuts and bolts to get my bambino housing back in place without it touching
The sharp of eye will notice that I'm using bolts instead of studs for the pulley mount as mine came loose !!! I also used two spacers (M17 x 24mm x 1mm) to give sufficient stand off for the fan and housing, they seem to work ok.
I'll get back when it's all running again - hopefully
Ian.

Greetings, well after all the two'ing and fro'wing with alternators, fans and fan housings it's done. The engine still wobbles some when running (see vid) but it does not chase me around the workshop
I was worried about the charging level, but after repair the alternator is ok. I have replaced the bambino thermostat housing too. I'll run it now and then as I cannot be bothered to take it off the stand - unless it's needed for the car that is
Ian.

https://youtu.be/hbN1xZ8-Mw0

That looks and sounds pretty smooth to me but I guess that you have the tick over revs up a little. Nice engine to have just in case. Is that the Panda 30 DGF carb on there?

Toshi 975 said:

That looks and sounds pretty smooth to me but I guess that you have the tick over revs up a little. Nice engine to have just in case. Is that the Panda 30 DGF carb on there?

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Hi Dave, yes it is, I need to change the complete jetting set one stage leaner and then it will be sweet. The engine was run on a rolling road with a Solex carb so the power will be down a little but still well over 30bhp @ 5000rpm.

Ian.