912 Generator Pulley Wheel

[leewiffen]

Recently my pulley wheel on the end of the generator shattered and jammed up
It jammed pretty bad and possibly damaged the generator
However I removed the damaged pulley wheel and replaced it, thinking it was just an old part.
The generator is pretty new and appears to be running true when turned by hand, but obviously at revs may be imbalanced
After fitting the new pulley I was getting a bad clunking noise which appeared to be where the rear pulley was touching the generator
Removed and put a shim to space it, but noticed the rear pulley was already showing signs of damage where it fits over the hub ( see image )
Any ideas what is going on ?
Maybe the generator is out of line and not spinning on a true axis, although when you turn it by hand there is no noise or movement
However when I refitted the new pulley and ran the car, there was a vibration through the fan housing, but when I turn it by hand, nothing is touching on the fan at the rear
Also, should the terminals on the generator be that close to the oil filler?
Maybe it is not the correct generator, or I have mounted it incorrectly on the fan?
See pictures
https://www.flickr.com/photos/95118177@ ... 1317826693
Ta
Lee

[Peter Graham]

Link to photos does not work.

Without photos, the most likely cause of your problem is not using enough shims. When too few shims are used, the generator pulley nut tightens against the generator shaft instead of the pulley halves/shim stack. The result is eminent destruction of pulley hub, halves and 'dog-earing' of the shim centers. You can run a few more shims than is recommended without causing any issues. Using shims to space the inner pulley half away from the generator body is perfectly acceptable as long as the generator and crankshaft pulleys are aligned.

Peter

[Peter Graham]

Originally Posted by leewiffen

Also, should the terminals on the generator be that close to the oil filler?

Yes, they can be especially for MY68/69 which have the large diameter generators. These photos are two different MY68 motors...