LOGIN  
Welcome to Classicgoldwings Chat Live Chat:   >  
Make a Donation and
Become a Supporting Member!
It is currently 2021-07-30- 15:54
Who Is Online: dan filipi, joedrum, quepsiphi18, trv .... 2 guests
Jump to:  

Portal » Forums » Repairs and Modifications » Alternator Conversion

Welcome to Classic Goldwings!
You are now viewing the forums as a guest which has very limited access to the forums.
Log in or create a free account.

Print view
Post new topic Reply to topic
Author Message

Offline

Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#1  Unread postPosted: 2019-08-03- 18:27

**** *
**** *
Site supporter

Topic author



Joined: 2012-06-09- 5:56
Last visit: 2021-05-18- 5:30

Total Posts: 1045
Active Topics: 109

Total Images: 5
Location: Centralia Illinois
Local time: 2021-07-30- 18:54
Country:  United States (us)
My Bike Models: 78 GL1000 Black
84 GL1200I Black
84 GL1200I Parts
85 GL1200I Gold
86 GL1200A Trike
88 GL1500I Yellow


Profile Personal album

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.
You do not have the required permissions to view the files attached to this post. You must LOGIN or REGISTER to view these files.

_________________________________



Top  

Offline

Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#2  Unread postPosted: 2019-08-03- 19:37

User avatar
**** **
**** **
Site supporter

Joined: 2011-10-17- 13:57
Last visit: 2021-07-28- 18:16

Total Posts: 2012
Active Topics: 109

Total Images: 44
Location: Chandler, Arizona
Local time: 2021-07-30- 16:54
Country:  United States (us)
My Bike Models: - '97 Valkyrie
- '90 Vmax
- ‘86 Vmax
- '85 Vmax
- ‘82 CX500 Turbo
- ‘83 ZN1300
- '79 CBX-Z
- ‘78 GL1000
- '78 CB750F project


Profile Personal album

I converted my '84 Aspy in '01. Cost me a heckuva lot more than $130. Like double. Sheesh.

_________________________________

“When I’m riding my motorcycle, I’m glad to be alive. When I stop riding my motorcycle, I’m glad to be alive.”- Neil Peart


Top  

Offline

Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#3  Unread postPosted: 2019-08-03- 21:03

User avatar
****
****
Site supporter

Joined: 2019-06-20- 21:21
Last visit: 2021-05-15- 10:16

Total Posts: 258
Active Topics: 5

Total Images: 51
Location: Christiansburg, VA
Local time: 2021-07-30- 19:54
Country:  United States (us)
My Bike Models: 81 GL1100
75 GL1000
82 GL500I
64 CA95
67 CA160
64, 65, 66 CA77
82 & 83 CB450SC
82 CM250C
67 T-20 X6
67 YDS3C-250
85 CB650SC
71 CB500F


Profile Personal album

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!

_________________________________

Virginia is currently experiencing some political & social difficulties, but nothing we haven't eradicated before!


Top  

Online

Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#4  Unread postPosted: 2019-08-04- 2:54

User avatar
**** **
**** **
Site supporter
Single Carb Club
C5 Club

Joined: 2009-12-08- 13:21
Last visit: Yesterday- 4:05

Total Posts: 19500
Active Topics: 208

Total Images: 1943
Location: chuluota florida
Local time: 2021-07-30- 19:54
Country:  United States (us)
My Bike Models: A bunch in the works
My Bike Logs forum link: https://www.classicgoldwings.com/forum/ ... .php?f=121

Profile Personal album

My YouTube Channel
Looks like the same fan I used on hooch

_________________________________

Image

thank god and hooch im gone


Top  
Post new topic Reply to topic


Print view |
LOGIN  
Welcome to Classicgoldwings Chat Live Chat:   >   It is currently 2021-07-30- 15:54
Who Is Online: dan filipi, joedrum, quepsiphi18, trv .... 2 guests
Jump to:  

Portal » Forums » Repairs and Modifications » Alternator Conversion

Welcome to Classic Goldwings!
You are now viewing the forums as a guest which has very limited access to the forums.
Log in or create a free account.

Display topics from previous:  Sort by  

Contact Us Terms of Use Privacy Policy

The views and opinions expressed at this public user forum are those of the authors and do not necessarily reflect the official policy
or position of Classicgoldwings.com, it's moderators or administrators, or it's forum founder or owner.
Any content provided by our bloggers or authors are of their own opinion, and are not intended to malign any religion,
ethic group, club, organization, company, individual or anyone or anything.


Copyright © classicgoldwings.com All Rights Reserved

Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group