Installing external alternator on 86 Aspencade

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Tom_Charlton

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Location
Centralia Illinois
My Bike Models
1984 GL1200I
1988 GL1500
Adding external alternator to 86 GL1200A – about $130 for materials.

Many thanks to Poorboy for the guidance in his excellent article.

Materials used:
1. 35 amp Denso Alternator - $53 from EBay total-power-part
2. Aftermarket Electric fan – $16.30 from EBay, funsport-USA
3. One 4” pulley, ½” center – $19.00 from hardware store
4. Aluminum rod, 1” X 6”.
5. One 28” X ½” V-belt, $5.99 from hardware store
6. 12mm X 1.25 X 60mm crankshaft bolt - $5 from hardware store
7. One 20mm long crankshaft spacer, cut from aluminum rod, drill center to 12mm.
8. 10mm X 1.25 X 130mm lower alternator bolt– $13 from special order
9. 3 6mm X 1.0 X 20mm bolts - $.10 from hardware store
10. Drill ¼” hole in center of two pennies (now they are flat washers)
11. One foot of 1” ID heater hose from NAPA - $2.50
12. 1 ¾” ID 90 degree copper elbow. $1.59 from hardware store.
13. 4 heater hose clamps.
14. Black wire and green wire for fan.

Construction steps
A. Remove lower front cowling pieces.
B. Remove radiator, remove fan from radiator.
C. Remove left horn.
D. Cut off front left upper engine support and save lower portion for bottom alternator spacer.
E. Remove timing belt covers, clamp covers securely to work surface and cut 1” hole at center for pulley shank.
F. Remove OEM crankshaft bolt, washer, and timing belt shield.
G. Grind flat spot on 12mm X 1.25 X 60mm bolt for setscrew engagement.
H. Install right timing belt cover.
I. Fashion bushing for pulley so 12mm bolt has no play.
J. Install pulley on 12mm bolt, tighten bolt & setscrew firmly using Loctite.
K. Install left timing belt cover. Put V-belt around crankshaft pulley.
L. Construct bottom alternator spacer from ½” ID steel pipe 85mm long and lower portion of left engine support. Wire welding time!
M. Place V-belt around alternator pulley and install lower alternator bolt (10mm X 1.25 X 130mm) and spacer. 12mm spacers/flat washers may be needed to align crankshaft pulley and alternator pulley.
N. Run charging wire (8-10 gauge) from alternator post to battery positive post area. Do not connect to battery yet.
O. Using flat steel 1/8” X 1.0” X 3.5”, construct top alternator bracket as shown. Holes are 9mm and 6mm, with 64mm center to center. Curve is necessary to clear frame rail.
P. Attach top alternator bracket to alternator and left horn mount bracket. Top alternator bolt is 5/16” X 1.25”; use 6mm X 1.0 X 20mm bolt for horn bracket bolt.
Q. Bottom radiator standoffs: Cut 2 pieces from aluminum rod to 1.75” long and drill 7/32” hole centered lengthwise through each piece. Drill ¼” hole 5/8” deep in one end of each piece. Tap remainder of each 7/32” hole to 6mm X 1.0.
R. Install standoffs on bottom radiator studs.
S. Install radiator on standoffs using 6mm X 1.0 X 20mm bolts and penny washers.
T. Modify water pump cover so inlet is horizontal versus vertical. Aluminum welding required.
U. Install bottom radiator hose.
V. Mount horn by twisting horn mount strap 90 degrees so horn faces right versus forward. Attach horn strap to end of horn mount bolt with 6mm nut.
W. Connect charging wire to positive battery post.
X. Mount fan on front of radiator and wire to push air through radiator.
Y. Put panels back on.

Ops checked good, 14.5 Volts @2000 RPM.

Again, many thanks to Poorboy for the original concept and his article.
 

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I hid the horns on my 81 GL1100 and my 82 GL500i under the front lowers like you have pictured here. Not exactly an alternator job, but I just didn't like the OE horn location, lol!
 
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