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Old 01-17-2010, 02:28 PM   #1
Tarka OP
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Location: Across the pond.
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My homemade conversion to fit a Mitsubishi alternator to my Ural

I`ve got two Ural combos...a yr2000 650 'Roustabout' and a yr2004 750 'Dalesman'.

The 750 has the Nippon Denso alternator,which is an ND alternator in a factory made custom casing fitted with a cushdrive acting as an adaptor to mate with the Ural timing gear train.

The 650 has the infamous Russian 'Hand Grenade' alternator.
I`ve had three of these alternators fail in the last four years and am sick of it...when they fail they either are short term repairable only to pack up again within a month or so,or not repairable at all.
They`re cheaper than the ND but still not pocket money...and there`s no warranty on them,not here in UK at least.

In any case,over here,the ND and the 'Hand Grenade' are currently 'Unobtanium'.

So,when the 'Hand Grenade' failed yet again on my 650,I put my 'thinking cap' on and also consulted my friend and very capable work colleague Jamie.

If the ND alternator is a proprietry alternator fitted with an adapted cush drive linking up into a custom front case (have a close look at yours if you don`t believe me)...then why not do similar for my bike???

We checked out the Internet and looked on eBay....and found a dinky little Mitsubishi alternator.
It was cheap enough to use as a 'try it and see' so I bought one.
In fact,it was less than a quarter of the cost of an ND one and about half that of a 'Hand Grenade'.

Lo and behold,it just about fitted inside the front half of the now gutted 'Hand Grenade' casing!!
The through studs even virtually lined up with the stud holes in the casing!
Jamie milled out the area around the 'hand grenade stud' holes and I chamfered the inner face of the casing.



We cut some stainless steel threaded rod to length,and welded a nut at one end of each to make some new custom length through studs.
Then we measured up and made some hollow spacers to allow the Mitsubishi alternator to be fixed to the front casing of the 'Hand Grenade' shell.
Pic below shows the prepared casing and the spacers.



Then came the sheer genius of Jamie.
He spent a fair bit of time looking,thinking,measuring and note taking.
Then he got the lathe in action......and worked his magic.
Not very long later,a shiny object was placed in my sweaty palm.
A stainless steel stub shaft....
Looking from the left of the pic below,this masterpiece in metal had a female thread to accept the male thread on the Mitsubishi shaft (where the locknut goes to retain the original,and now not used,beltdrive pulley)..then a 'land' to accept a double row bearing that fits the bearing housing in the 'hand grenade' front case...then a turned down area to accept the original Ural alternator drive gear (with a keyway cut in to accept the original Woodruffe key)....then a male thread to accept the original Ural alternator lock nut,along with a through hole to accept a split pin,as per original.



Absolute...total...sheer genius!!!!

We`ve effectively designed and created a conversion kit.
Here`s the fruits of our labour in dismantled form.....



Here`s the bits with the Mitsubishi alternator...



Of course,the proof of any pudding is in the eating...

Did it fit my 650 ?

It went straight on,using the original fixings,but needed a wiring mod...just wanted a 'switched positive' so I spliced into the 650 ignition coil feed.
Then the airbox was about 10mm rearwards of its mounting,so I just dished the front of the airbox casing and then all the original brackets and intake hoses were useable.


Did it work ??

The charge lamp went out the moment the engine cranked over.
It doesn`t light at all when the engine is running.
With the 'hand grenade',the charge lamp would be on until about 20mph and occasionally flicker when running.

Does it charge ??

At tickover it`s producing 13.2 volts.
Once revved,from tickover onwards it produces 14.7 volts.

Result !!!

TOTAL SUCCESS !!!


THANK YOU,JAMIE !!!!


Here`s the masterpiece all assembled.....

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Tarka screwed with this post 01-17-2010 at 02:47 PM
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Old 01-17-2010, 03:48 PM   #2
wyowillys46
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The ND alternator is actually used in a lot of forklifts and a few little cars, like the Suzuki Samurai, Chevy Sprint, and Daihatsu Charadl. I want to say it's also used in a Renault. Not sure of which model though.
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Old 01-17-2010, 04:01 PM   #3
uraldog
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excellent-- great job--- but-- you knew that was coming--- from what I see it's a damn good fit, the area arround which the carrier bearing is going to be residing may need to be beefed up like the russians did to the adapter in the 2007 update --since your adapted version does not have a cush drive [ correct me if I'm wrong on this ] this bearing cavity may need to be watched to see if any metal fatigue arises in that area and causes any wobbling and mis alignment issuses -- please don't take this critique the wrong way . I think what you've done is fantastic and if it works without the reinforcement I suggested this will really help keep allot of old Russian iron on the road--- GOOD ON YA
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Old 01-17-2010, 04:08 PM   #4
Tarka OP
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Quote:
Originally Posted by uraldog
excellent-- great job--- but-- you knew that was coming--- from what I see it's a damn good fit, the area arround which the carrier bearing is going to be residing may need to be beefed up like the russians did to the adapter in the 2007 update --since your adapted version does not have a cush drive [ correct me if I'm wrong on this ] this bearing cavity may need to be watched to see if any metal fatigue arises in that area and causes any wobbling and mis alignment issuses -- please don't take this critique the wrong way . I think what you've done is fantastic and if it works without the reinforcement I suggested this will really help keep allot of old Russian iron on the road--- GOOD ON YA

Yeah...thanks for that advice,Uraldog.

Nope..we`ve not fitted a cushdrive.

The 'Hand Grenade' didn`t have one,either,anyway.

It`s all been checked for true...and we`ve got a double row 2RS bearing in the housing...but seeing as it cost next to nothing to create and has saved about 300 it`s worth a tryout !
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Old 01-17-2010, 04:12 PM   #5
Tarka OP
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Quote:
Originally Posted by wyowillys46
The ND alternator is actually used in a lot of forklifts and a few little cars, like the Suzuki Samurai, Chevy Sprint, and Daihatsu Charadl. I want to say it's also used in a Renault. Not sure of which model though.

Thanks for that.
I`m aware of the ND applications,but if you bought one from a car suppliers,it would be a plain ND alternator with a belt pulley on it.
That won`t go straight on a non ND equipped Ural unless you already have the special casting and cush assembly used by Ural in place of the ND pulley.


My Mitsubishi one is for a forklift truck.
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Old 01-18-2010, 12:46 AM   #6
cpres
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Go do some testing by riding that bad boy. Looks real good now lets see what it does long term. It is great to have friends who can and will help us with our toys/vehicles.
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Old 01-21-2010, 01:00 PM   #7
Mr. Cob
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Howdy Tarka,

Great mod that you and your mate came up with.
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Old 05-25-2010, 03:45 PM   #8
KidJedi
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I am trying to follow in your footsteps, can you send me some info on the custom adapter so I can have one machined? and more info about the alternator that you used? Thanks
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Old 05-25-2010, 04:26 PM   #9
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