Bob M

1 - The alternator may not be spinning fast enough at startup to "turn it on". Try running the engine up to full speed. If the light goes out and the ammeter now indicates a charge, the problem is solved. (Once the alternator is turned on it will continue to charge at lower RPM). If this turns out to be the problem consider installing a smaller pulley on the alternator to spin it faster.

2 - The warning lamp bulb may be too small. The bulb must draw at least 0.2 amps in order to turn on the alternator. (A #1850 or #168 side marker/instrument panel bulb is the right size.) You can verify by momentarily shorting the #1 and #2 alternator terminals together with the engine running. If the alternator charges (and the lamp stays dark after you remove the jumper) it means the bulb is too small.

Post back what you find!

- Visit your local starter/alternator shop (or wrecking yard) and inquire.

- Go to a power transmission products house or catalog (like WW Grainger - link below) and order one that fits.

- Or do what I've done - modify your existing pulley: Remove the pulley and chuck it in a lathe . Use a cutoff tool to split the pulley at the centerline (at the base of the belt groove). Now insert 2 or 3 flat washers between the pulley halves when bolting the pulley halves back onto the alternator shaft. This "opens up" the groove, effectively reducing the pulley pitch diameter and making it spin faster.

• Grainger sheaves