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Great description, thank you! So $50 for a rotor, $25 for a pulley, I'm half way to a new clone setup right there and that doesn't count resistors or anything else that's gone wrong. Smart money says go clone, along with almost every member here. I'm thrifty but not stupid, so I'll go clone...

Point me to this?

She might not be charging I appreciate the input so far guys. So I finally got around to testing my alternator output and it's low. 24.4v, 22.1v with the lights on as the TM says. The TM says to remove the hex plug and turn the adjusting screw ccw to increase the output volts to 27.8 to 28.2v...

Let me ask, how hard is that rotor to replace? I appreciate the exploded diagram above! It looks straight forward, are the bearings pressed on the rotor shaft? Will I need any special tools? Thanks!

You guys probably know better than I but why not? Is that little ground up area behind the key that bad? It doesn't go all the way around. Several washers on the front overcame the stripped threads and gave the nut good threads to grab on to. I just don't want to throw too much money at an old...

Thanks all. I was able to find a replacement pulley for cheap and will slap it on when it arrives.

Got it out and apart... Got it out and apart. Indeed the key on the shaft ate the inside of the pulley. The key faired fine and just needed clean up with a file. Same for the inside of the pulley. With them both cleaned up they just slide right together relying on the nut to hold them together...

Think I'm better buying the alternator and pulley myself or going for this? http://www.wolverinetechnologiesllc.com/M925Alternator.html I'm not sure where to find a pulley by itself.

I'll have to pull it and look but I wonder what forces in play keep the pulley from being drawn down tight against the housing? I think it chucked it's first belt right after I got it...

NHC250 alternator pulley loose, not charging?! I've lost count of the number of belts it's thrown in the last year, prolly 6-8. I finally identified the problem as a loose alternator pulley that wiggles and throws belts off. I tightened it down once only to have it come loose again. I was going...