Overview: This conversion is easily accomplished if some preparation is taken before beginning.

Referring to illustration #1, note here that the original alternator on right has a single piece pulley, the conversion in this article uses the two piece pulley shown on the XT 6 alt. on the left.

Looking at this illustration a couple of problems are evident.

1. The pulley does not line up exactly with the original.

Filing or sanding of the mounting ear will correct this.

2. The rear mounting ear is not aligned with the original.

The addition of a spacer will fill this misalignment.

What is not evident is the fact that the mounting bolt holes for the new alt. are larger than the original. Use of 3/8" bolts threaded into the mounting bracket is a simple way of correcting this. The bracket holes are a perfect size for simply running the 3/8-16 tap into the hole.

3/8 – 16 tap

3/8 – 18 x 1" bolt

3/8 - 18 x 1.5" bolt

7/16" wire eye connector

0.170" spacer washer

Custom made "T" bushing (see drawing)

1" longer than factory alternator belt

2 piece pulley from original alternator (see page 6)

Hold pulley with pipe wrench while removing nut.

Remove pulley from XT6 alt.

Place custom spacer on shaft of XT6 alt. Followed by pulley from orig.alt.

Note: thicker pulley half must go on nearest alt.body.

Using serviceable "lock tight" secure pulley with nut.

Using file or sander, remove 3/32" from mounting surface of upper forward mounting ear.

Using suitable socket (5/8" 3/8 drive) and 3/8 x 1.5" bolt and nut, press upper rear ear spacer fully forward.

Using 3/8 – 16 tap thread both upper mounting holes of bracket.

Remove small eye from large wire for alternator output.

Solder and or crimp large eye on wire.

"T" shaped connector can be used "as is".

Place alternator in battery tray and secure output wire and "T" connector. Plastic guard from XT 6 alternator output post should be employed, as the mounting position is different from the original. The original rubber boot should also be used on the "T" connector.

2] Place spacer in between the rear mounting ear and the bracket, thread 3/8 x 1.5" bolt into bracket. Do not tighten.

3] Place new alternator belt in place.

4] Thread original lower pivot locking bolt into mounting ear.

5] Lift alternator ( do not pry) by pulling outboard side.

Note: There is still some play in the mounting bolt holes, using this tightening method will align the alternator in the correct position.

6] Tighten all mounting bolts. Beginning with upper 3/8" mounting bolts.

Conversion is complete.

Illustration # 1

Spacer drawing

Dimensions are

0.661

0.590

0.300

0.285