Dynalite Pulley Replacement

• Remove pulley from existing dynamo along with the spacer and any spacer washers.
• Remove nut, washers and cardboard tube from the Dynalite.
• Fit the spacer and any washer removed from the dynamo to the Dynalite so that the spacer is proud of the casing.
• Drill out the pulley with a 17mm drill.
• Fit the pulley to the new Dynalite nut, using washers to ensure the pulley is gripped between the nut head and the spacer in the same relative position as on the dynamo.
• • Tighten the nut with an air gun if possible or by holding the shaft end with the screwdriver slot. Do not hold the shaft by inserting bars into the commutator. We recommend the use of a Loctite type product on the thread on final assembly.

Important Information

Please ensure that the Dynalite is correctly earthed through the mounting bracket, particularly if the engine and/ or bracket have been recently painted or powder coated.

Never allow a 12v supply to contact the warning light connection (except via the bulb). Never allow the warning light connection to earth whilst the car is running.

Warning light bulb should be 2.2w to 3w and must be installed for the Dynalite to work correctly.

The battery must be providing a minimum of 12v both at the battery terminal and via the warning light bulb for correct operation of the Dynalite.

Conversion from positive to negative earth

The following instructions cannot hope to cover all cars in all situations so they are intended as a general guide to requirements and careful thought should be given to all electrical equipment fitted to the vehicle.

Most positive earth vehicles are of an age that no modern electronic equipment was fitted but that may not be the case now as electronic ignition, fuel management systems and electric fans could have been fitted along with a radio, all of this type of equipment needs to be converted. In most cases, the manufactures instructions or the manufacturers themselves would need to be consulted for instructions on how to convert the units if possible. Items such as the fans just need the wires changing over and in the worst case, it is often possible to electrically isolate a radio and wire it the other way round (or just buy another modern radio if the look is unimportant). Just take care to check out the items that are not standard on the car.

Having determined what to do about any special equipment, disconnect the battery. You will probably have to turn the battery around so the cables will reach or arrange to amend the cables so they will re-fit to the battery when you come to re-connect it the other way round. The battery terminals are mostly slightly different sizes so you will need to swap over or better still take the opportunity to renew the clamps.

We assume you are changing from dynamo to alternator so that we are ignoring having to change over the dynamo by 'flashing' it.

• Now change over any of the special equipment we have discussed above.
• Swap the positive and negative terminals on the coil.
• If you have an ammeter reverse the main wires on this (It will just read backwards if not).
• If you have a heater blower motor this may need to be changed over or it will be blowing out of the car not in and then not very effectively. If access to the wires is difficult, test it by checking airflow before going to the bother of removing the motor to get to the wires.
• Most cars with electric fuel pumps are not polarity sensitive but a few with more modern pumps may be fitted with a diode. If this is the case, the diode needs to be swapped round by cutting and soldering back (or replacing). You can normally see the diode by removing the electrical cover. Do not confuse a capacitor to prevent sparking with a diode as this is not polarity sensitive. Do not swap cables on a fuel pump as you have potential for sparking due to the case being opposite polarity to the body of the car.

The wiper motor may run backwards so prior to switching them on, pull the wipers off the knurled nuts and look how the nuts turn when switched on and where they park. Re-fit the blades so they park in the correct place and wipe the screen not the bonnet.

If you have an electronic tachometer, it will need to be converted and it is possible that this can also be done by some internal modification but like the radio, it is probably better to purchase a new unit.

When completed re-connect the battery and check all electrical equipment functions correctly.

Instructions for converting many cars are available on the internet with much more detail on particular types and you should check to see if this applies to your car as it will cover all the specific requirements for your vehicle.