100 amp Alternator Pulley Switch

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  • rcsmith727
    • Apr 2017
    • 49

    • Denver, CO

    • 1995 Nautique Super Sport

    100 amp Alternator Pulley Switch

    Has anyone else had trouble swapping pulleys on the 100 amp alternator upgrade? My v pulley from the old alternator seems too small to fit on the 100 amp alternator threads. My old alternator post is 0.62 inches wide and the new one is 0.66 inches, so it's close but enough that I'm struggling to fit it on. The old pulley is from a 1995 Nautique Super Sport, and I assumed the upgrade kit would fit the older boats. Hoping I don't have to order a new $50 pulley. My old pulley also has a key on it, whereas the new one has no key

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  • Jimboslice54
    • Apr 2017
    • 25

    • Fort Worth, TX

    • 2011 Sport Nautique 200 - EX343 former: 04 196 & Sportster LX, 95 Ski Nautiqe

    #2
    You will have to order the new mondo pulley.

    Same thing happened to me. As an alternative I tried to bore mine out just a bit to make it work. However in doing so it exposed the seam were the halves are welded together. Enough so that it looked to me like it would be very easy to split. Ran it for one weekend like that no problem until the new one arrived.

    Sent from my SM-G930V using Tapatalk

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    • rcsmith727
      • Apr 2017
      • 49

      • Denver, CO

      • 1995 Nautique Super Sport

      #3
      Thanks Jimbo. That's what I was afraid of. Sounds like the newer GT40s don't have this problem. My original alt is a Prestolite 51amp in case anybody else runs into this issue

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      • rcsmith727
        • Apr 2017
        • 49

        • Denver, CO

        • 1995 Nautique Super Sport

        #4
        Jimbo, the Mando Pulley rubs the 100amp alternator when I use the spacer included with the 100 amp kit. My old spacer didn't fit on the post, so I'm ordering the Motorola Pulley to see if it fits.

        Nautique asked me to send them the two alternators because they haven't had this problem before.

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