Alternator cable connections

While replacing my belt drive with the new kit, I noticed that the alternator wiring was suffering as a result of the twisting and general flexing of the cable while trying to get the clearances correct. I have sealed the hole in the inner case where the cable passes through to ensure no gunk gets in, but this makes it difficult to disconnect the wiring, and the nthere is the issue of getting the bullets through the grommet.

Then it occurred to me that if the bullet connectors were moved inside the primary chaincase, it would be child's play to disconnect the wires, remove the stator and play with the clearances, instead of the usual performance of hanging the stator from a bit of wire etc.

Since the belt drive runs dry, no problems with oil, so I really don't see any disadvantages - actually, since oil is an insulator, this should also work with a chain drive as well.

This is not a bad idea, especially with a belt drive. But the downside to this is if your regulator dies (as my Pod did a couple months ago) then you have to pull the primary to replace it, which is a distinct hassle if chain drive.

There are grommet kits of various sizes available...this was my solution, the grommet defeats abrasion while holding the wiring in place. The bullets slip through individually.

I use a 2 wire alternator. I have a small two wire weather pack connector inside the primary. Wiring needs to be routed so it is out of harms ways in the primary. I have a set of bullet connectors in the engine gearbox cradle area on the alternator wires for times when I have to remove the inner primary or swap out a burned up regulator/rectifier. Everything from the back of the inner primary to my regulator rectifier is in split wire wrap to protect it and to give me access to the bullet connectors if need be. All shade tree engineered.

This is maybe a bit "out there", but it just came to me reading this; Would it be possible to attach a double sided connector of some sort permanently to the inner casing and plug the cables from the alternator on the inside and the cables to the regulator on the backside? Please note that I have not thought this through in any way....

fiatfan said:

This is maybe a bit "out there", but it just came to me reading this; Would it be possible to attach a double sided connector of some sort permanently to the inner casing and plug the cables from the alternator on the inside and the cables to the regulator on the backside? Please note that I have not thought this through in any way....

Click to expand...

Very doable if you can find a small enough connector and have clearance for the connector half on the backside of the inner primary. When I say small I mean overall length once assembled with the wires. I looked into it, but not hard enough. It was easier for me to use a two wire weather pack style connector.

Weatherpack and connectors like that (Deutsch, etc) are easy to disassemble and get through the small hole.

fiatfan said:

This is maybe a bit "out there", but it just came to me reading this; Would it be possible to attach a double sided connector of some sort permanently to the inner casing and plug the cables from the alternator on the inside and the cables to the regulator on the backside? Please note that I have not thought this through in any way....

Click to expand...

Every connection you add to the system increases the number of electrical failure points. It would also increase the possibility of a primary drive oil leak. Remember the KISS principle! The oil leak issue doesn't exist for Steve. I find it easier to simply keep a few of the primary grommets on hand. Rather than applying RTV to the grommet, simply replace the grommet. They certainly are cheap enough. The best way to move the Lucar connectors through the grommet is to fold 1.5" to 2" of one wire over on itself. That way, you are only trying to get one Lucar connector through the grommet at a time. I'm sure that Norton's original reason to not follow fiatfan's suggestion had more to do with cost, than reliability.