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Hi SB If you have a 3 pin sealed bean unit, then you have the high beam terminal, the low beam terminal and a shared earth for both. There should be a small hole in the reflector coating (not in the glass) on the inside of the unit for the side light bulb light to shine through the glass from...

If that is your only concern, stick with the dynamo; light flicker is perfectly normal for dynamo at low rpm. Also new brushes will take a little time to bed in. Peter Good

Sorry, never come across this before, but it certainly doesn't sound right to me. The alternator should be a snug fit onto the cradle of the stand, making even contact along the entire interface. If there is a gap as you say then possibly the tinware is not correctly seated in place, or the...

Fitting the hazard switch in is perfectly doable with what you have. Starting at the hazard switch follow a later (e.g.1972) diagram. You will need one extra connection to the fuse-box, red 2.5mm cable and suggest using fuse 10 output. Peter Good

If the spacer behind the pulley was missing, you would not be able to turn the shaft; it would be pretty much locked solid. There is much debate on this matter, but my view is most of issues like you report is due to insufficient shims in total. Peter Good

If the indicators are working and the headlamp flasher operates and the high beam comes on, then your indicator switch is working fine and OK. Provided there is a click from the relay when you are trying to change from high to low or visa versa, then the relay is the culprit. Some of the...

Possibles: - Out of balance alternator rotor Bent / damaged alternator shaft Top / Bottom pulley not in line Top Pulley set up / adjustment Damaged pulley As ozziedog suggests photo's will help... Peter Good

It is 10mm difference.

Sorry, but I think you have still missed the point. If you are relying on 'flat ends' and 'D ends' once installed and operational then that is part of the evidence that it is not set up correctly. The pressure correctly applied by the pulley nut all but negates the need for any of the above...

Mike, on a stock set up, the solution is more often than not a lack of shims as you suggest. As a guide, if you check some of the period photos published by VW, the pulley nut is always at the end of the shaft with no threads visible. Conversely, if 2 or more threads are visible, it is a good...

Sorry to question your diagnosis, but I disagree with the cause of the failure. What is happening is that the pulley nut has effectively bottomed on the shoulder just below the threads on the alternator shaft. As a consequence what feels like a fully tightened pulley nut is in effect applying a...

In days past I worked for several of the big names in starter motors. Our stats showed over 60% of old VW Air-cooled starters that had 'failed' were perfectly OK except that they had run with a worn bush. That bush is very sensitive to wear; wear that is not easily visible to the eye. Don't take...

It could indeed be the regulator, but spinning the dynamo as if a motor only proves the basic copper windings are all in place and OK. It doesn't prove there is enough residual magnetism to start up. You really need to disconnect the regulator fully at the dynamo (make cable ends safe) use a...

Very likely your dynamo is fine. However, having been laid up for a few months it has probably just lost its 'residual magnetism.' You will need to repolarise the dynamo; just do a search on here or a search engine for Dynamo Polarisation. Peter Good PS My advice is stick with your dynamo. The...

Hi Roy, The regulator part number you have quoted is a US aftermarket alternator regulator, for the early externally regulated alternators. Most commonly with 0120 400 836 Bosch alternator part number if the label is still there. All replacement alternators are internally regulated, so it is...

Water and a splash of vinegar every time Peter Good

You have the answer to the first question in the posting by rlepecha earlier today..... As for the alternator it is very dependent on the exact part number as to whether the regulator can be replaced. Original ones had an external regulator, but the alternator itself was pretty rubbish so I...

Dave, I think you are referring to the main battery positive cable to the M8 stud terminal of the starter motor? The minimum is 25mm2 and most (nearly all?) are covered with black insulation, although red is more appropriate. If you have a non-stock higher powered starter you may need to use...

Si, Without the pulley and all the other 'end components' fitted there will and indeed should be a small amount of axial play. Without any it will cease up or even break-up as it warms up. However, on a properly reconditioned unit the bearings should be a really tight fit that axial movement...

As others have stated, the black cable from the loom goes to the coil, and one of the two spade connectors, and it does matter which one! On Bosch coils and similar the 2 low tension spade terminals are DIN marked '15' and '1' respectively - the black cable needs to go to the 15 terminal. On...