GL1100 alternator conversion (how I did mine)


Step-by-step tutorials on how to maintain and fix your GL1100
  • Sponsored Links
User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sat Sep 14, 2013 12:04 am



We all enjoy seeing what others come up with, different ideas is where it's at. I for one would love to see your idea's ... I have a video somewhere on the volts at idle, I know it was just above 14volts with everything on at idle just like a automobile....I'm just thrilled with it...Can thank the guys before me enough for talking me into it and boy it took a while before I went there.. :D Show us..



User avatar
Joecop
Posts: 93
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: GL1100 alternator conversion (how I did mine)

Post by Joecop » Mon Oct 14, 2013 8:06 pm

Just an update I have about 800 flawless miles on the conversion. Didn't get to ride much with life getting in the way. But I did pick up a red led light that I installed for the low voltage indicator. It works great. It's mounted just under left speaker.
:D
Attachments



User avatar
roadwanderer2
Posts: 4342
Joined: Thu Aug 08, 2013 4:03 am
Location: Tucson Arizona
Motorcycle: previously owned 83 GL1100A aspencade traded for a motorhome, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. now own-1986 GL1200 aspencade SEi
Contact:

Re: GL1100 alternator conversion (how I did mine)

Post by roadwanderer2 » Sat Feb 22, 2014 6:50 pm

people, i just have to say you guys are wonderful with all your detailed pics, paragraphs, circles and arrows, and explaining every step of this conversion process. even though im not having any voltage problems right now, im DEFINITELY going to keep all this information handy "just in case" i need to do this on my '83 1100 aspy. thanks to all those that made this VERY informative reading.

Stuart, a.k.a. roadwandrer2.

User avatar
roadwanderer2
Posts: 4342
Joined: Thu Aug 08, 2013 4:03 am
Location: Tucson Arizona
Motorcycle: previously owned 83 GL1100A aspencade traded for a motorhome, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. now own-1986 GL1200 aspencade SEi
Contact:

Re: GL1100 alternator conversion (how I did mine)

Post by roadwanderer2 » Sat Feb 22, 2014 7:20 pm

hey littlebeaver, if your the one that has all those pioneer speakers on the front of your bike, yes, i saw it. cant believe the higher voltage output it made with all your electrics running even at an idle.

Stuart.

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sun Feb 23, 2014 9:11 pm

The only thing I have done to this conversion since I have installed it is tighten the belt a hair... Todd [Road Rogue] did a awesome right up on this conversion..... :D

User avatar
roadwanderer2
Posts: 4342
Joined: Thu Aug 08, 2013 4:03 am
Location: Tucson Arizona
Motorcycle: previously owned 83 GL1100A aspencade traded for a motorhome, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. now own-1986 GL1200 aspencade SEi
Contact:

Re: GL1100 alternator conversion (how I did mine)

Post by roadwanderer2 » Sun Feb 23, 2014 9:15 pm

yes he did, it was a very detailed writing on it. im gonna print it out and have it right next to me while im doing it on my bike so i don't make ANY mistakes and do it right the first time. :D

Stuart.

User avatar
DJnRF
Posts: 353
Joined: Fri Oct 04, 2013 8:50 pm
Location: FINALLY! Moved to a new home in Creve Coeur, IL.
Motorcycle: 1981 GL1100i Interstate
And, many others since I started riding. Started on a Harley in 1956.

Re: GL1100 alternator conversion (how I did mine)

Post by DJnRF » Wed Mar 19, 2014 1:37 pm

Dang! It has taken me a couple of hours just to go through
all of this information, and instructions. I have been trying
to figure a way to improve the alternator system on my
motor, and now I have the way. I made a change years ago
when I had my 750 so as to operate the high power Motorola
radio system along with all the extra lights and PA/Siren
system. That one was much easier. I still have the tool it
took to get into the factory alternator where I actually was
able to make the change. Now that I no longer have my
garage, I am going to have to build one just to fix my
motor with a new alternator system. This is going to be a
real strain on my brain as I am no longer paid to think.
I have even copied and saved all of this to a Word Doc.
to have just in case something happens to my PC. I will
have a full print-out saved to hard copy as well as CD.

Thanks much.
Dave.
"Survival is one's own ability to cope with and overcome any adverse or threatening situation, condition, casualty or event." ©Dj 1969

electrical magic
Posts: 14
Joined: Tue Jun 24, 2014 9:51 pm
Location: lemitar, new mexico
Motorcycle: 1982 suzuki 850 g

Re: GL1100 alternator conversion (how I did mine)

Post by electrical magic » Mon Jun 30, 2014 3:00 am

any DETAILED info on how to wire the geo metro alternator to the electric system ?

the alternator / stator replacement idea is starting to branch out......
i am looking forward to getting rid of the hot hot hot hot hot.......... shunt stator .


i need detailed info on how to wire up the alternator to my cycle .



AL .

electrical magic
Posts: 14
Joined: Tue Jun 24, 2014 9:51 pm
Location: lemitar, new mexico
Motorcycle: 1982 suzuki 850 g

Re: GL1100 alternator conversion (how I did mine)

Post by electrical magic » Tue Jul 08, 2014 1:01 am

here is plan #1).

THIS 1982 suzuki gs850g is a shaft drive.......... suzukis first shaft drive........ it was advertized as a sport touring cycle .
( so it a sort of in your leauge...........kind of ?).

if you look at the pictures of the 850 suzuki engine........ you will see the width of the mounting area where the n/d alternator will go .
RIGHT OVER THE TOP OF THE STATOR COVER.......... IT WILL LOOK LIKE THE #8).

PLENTY OF WAYS TO FABRICATE THE MOUNTING BRACKETS.......... SHOULD BE NO PROBLEM MOUNTING IT ALL TO THIS AREA .

(maybe a hole/s drilled down through the engine fins with the new mounting plates ???????????????????).
will have to see........... when i do this VERY NESSASARRY PROJECT .

the other picture is of the inside of the stator cover..........

what i plan to do is add a sealed bearing to the stator cover (& maybe an extra plate of aluminum to the outside of the stator cover).
this extra plate will be round & fit closely to the original stator cover with a bearing insert machined into it to hold the sealed (oil) bearing for the small shaft that has to extrude from the crank through the bearing to provide the area for the pully to mount to .

have you ever seen a small aircraft with wheel covers on the small wheels ?
it is this type of an alternator cover i am thinking about mounting to cover the alternator & the belts, pullys etc..............

i have got to do this .......... my stator is flat ready to burn up.......... i do have the new style reg/rec......... a sh 775 that cost me $80.00.
i will go ahead & install this new (3 times bigger than stock) reg/rec........... as a back-up .
[ it may be that the alternator will work perfect........ & i can remove the sh775 reg/rec permantly] .
{ & take out the stator, the rotor & magnets for good}

i am very sure that the new alternator WILL BE PERFECT !!!!!!!!!!!

if you look at the last picture........ you will see the suzuki side cover ;
a 3/8" round plate will be either welded or fastened to this side cover...... with a sealed bearing mounted to it........ the bearing should be wide enough to not only go through the 3/8" plate ..... but also the stator cover , the bitch-in pully shaft sticks out about an inch & a 1/4 , with a keyway & of course a bolt !.

i am really looking forward to this....... got to do it............& thanks to this GOLDWING DOC`S.......... i`ll make it !.

i will do a tutorial on this installation & post it for all to see & use.......... my engine gets so hot i am suprised it has`nt burned up.....
i am dreaming of some day in the near future ............. riding down the hwy.......... with my motor running strong, powerful & of course COOOOOOOOOOOOOOOL !

i don`t think that is toooo much to ask .............after all the $ has been spent .

AL.
Attachments











User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sat Mar 28, 2015 11:53 am

This information can be very useful for those seeking a special 2" pulley for the alt. with a 15mm bore,,, I finally found it,,it doesn't matter if there are more than 3 ribs, http://store.alternatorparts.com/2482264--.aspx this will fit the Nippondenso Alt. that we use for this conversion...It took me looking through so many sites I gave up several times but today I hit the jackpot....I know I can be very annoying at times but I do a lot of research to help the next guy....I got very luck because the alternator shop had a 2" pulley in house...

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sun Mar 29, 2015 8:46 pm

we got some really nice weather here in KC Todd, I went to work on my Motorbike and was playing with other alternators, the one you show is the ticket man,, it's really a simple bolt up,,, I did some more trimming on steel here and there and I made a leather cover to hide the rear of the Alternator. Looks good and the wind won't blow it away... :lol: I might change to black screws, those are self tapers...


I should make a pouch there man... :shock: I might install snaps for the leather for quick removable... :shock:( Like a kid in a candy store I swear)....

User avatar
RoadRogue
Posts: 2052
Joined: Sun Jun 06, 2010 10:51 pm
Location: southern Okanogan BC, Canada
Motorcycle: 1997 1500SE

Re: GL1100 alternator conversion (how I did mine)

Post by RoadRogue » Sun Mar 29, 2015 9:31 pm

nice touch with the coverup, keep an eye on it to make sure it is not blocking off the air supply that keeps the alternator cool. Thats where the regulator is and Im not sure of the direction of the airflow over it. Mine was just painted black to blend in, but I like your cover. It matches the one on the left fairing pocket. 8-)
Ride safe, Todd
Over night campers welcome

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sun Mar 29, 2015 9:47 pm

Yeah, I left it open on the underside for air flow should be find...Pretty sure it blows back...from the pulley...I'll find out if I get a leather balloon...LOL :lol: If it blows the other way I will remove it and paint the cover as well....thanks Todd :D flat black or gloss, ???? LOL I have extra parts for this alt. now..

Alemayehu
Posts: 48
Joined: Fri Oct 03, 2014 3:21 am
Location: Christchurch, New Zealand
Motorcycle: 1983 Honda GL1100
1987 Honda GL1200

Re: GL1100 alternator conversion (how I did mine)

Post by Alemayehu » Mon Mar 30, 2015 6:48 am

Great Job I admit I have to learn more.
God bless!

joe1981jones
Posts: 1
Joined: Sat May 02, 2015 9:31 am
Location: milwaukee Wisconsign Usa
Motorcycle: 1980 Honda GL1100

Re: GL1100 alternator conversion (how I did mine)

Post by joe1981jones » Tue Jul 21, 2015 9:59 pm

Ok Im a newbie with my dad's 1980 gl1100 I'm trying to keep running after he passed away. Anyone in the milwaukee area willing to do this conversion for me on it? I also needs all the rear brake parts mine went metal/metal and is done for.

User avatar
Joecop
Posts: 93
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: GL1100 alternator conversion (how I did mine)

Post by Joecop » Wed Jul 22, 2015 8:16 pm

Welcome....get on eBay, those brake parts are cheap...u need no other information but this site to do almost anything to your bike, so don't waste ur money on a manual. There are a lot of experts and just McGiver types on this site to keep it running forever. :D

User avatar
Choppir
Posts: 15
Joined: Tue Dec 03, 2013 12:40 pm
Location: Panama City Florida
Motorcycle: 1982 GL1100A Aspencade

Re: GL1100 alternator conversion (how I did mine)

Post by Choppir » Tue Aug 25, 2015 1:46 pm

Great article I am having this done to my bike any idea on the man hours to get er done? :?: 8-)

User avatar
RoadRogue
Posts: 2052
Joined: Sun Jun 06, 2010 10:51 pm
Location: southern Okanogan BC, Canada
Motorcycle: 1997 1500SE

Re: GL1100 alternator conversion (how I did mine)

Post by RoadRogue » Tue Aug 25, 2015 11:22 pm

If you have all the bits together and have a welder you can install it in a weekend, easy...... 8-)
Ride safe, Todd
Over night campers welcome

User avatar
Joecop
Posts: 93
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: GL1100 alternator conversion (how I did mine)

Post by Joecop » Thu Aug 27, 2015 10:47 pm

:D Took me over the winter....whoever is doing it give them time....don't rush it.....u want a quality job.

User avatar
Choppir
Posts: 15
Joined: Tue Dec 03, 2013 12:40 pm
Location: Panama City Florida
Motorcycle: 1982 GL1100A Aspencade

Re: GL1100 alternator conversion (how I did mine)

Post by Choppir » Sun Sep 27, 2015 12:49 am

Hi, I did the conversion on my bike, but am having problems with the bike running very hot, the fan comes on but the bike won't cool down. I put new antifreeze and no leaks, what do you think could be the problem?

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: GL1100 alternator conversion (how I did mine)

Post by littlebeaver » Sun Sep 27, 2015 10:58 am

I know it gets pretty hot down that way but it should still cool down with the fan, the only other thing I am thinking of is the water pump, I have not had this problem, are you sitting in traffic a lot when it gets hot like that? Or is it getting hot just on a daily....? Is it climbing up to the red? the highest mine has gotten in traffic was about 3/4 up and the fan running the whole time..

User avatar
roadwanderer2
Posts: 4342
Joined: Thu Aug 08, 2013 4:03 am
Location: Tucson Arizona
Motorcycle: previously owned 83 GL1100A aspencade traded for a motorhome, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. now own-1986 GL1200 aspencade SEi
Contact:

Re: GL1100 alternator conversion (how I did mine)

Post by roadwanderer2 » Sun Sep 27, 2015 11:12 am

the only time mine ever climbed up to almost the red line is when i got stuck in "stand still" traffic out on the interstate due to a vehicle accident and the traffic was going down to one lane for about 6 miles. once i got past the wreck and got out into open air, the temp needle went back down to half way.

stuart.

User avatar
Joecop
Posts: 93
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: GL1100 alternator conversion (how I did mine)

Post by Joecop » Sun Sep 27, 2015 12:07 pm

I would start with the thermostat then the pump. Did you burp out the radiator good check the level of radiator fluid? I haven't seen the slightest change in temps then again MI isn't the hottest state in th Union.

tomsfltc
Posts: 1
Joined: Fri May 06, 2016 8:09 pm
Location: Titusville, PA
Motorcycle: 1989 FLTC

Re: GL1100 alternator conversion (how I did mine)

Post by tomsfltc » Mon May 09, 2016 5:21 pm

Will this pulley work on a 1200?
Thanks
Tom

User avatar
Joecop
Posts: 93
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: GL1100 alternator conversion (how I did mine)

Post by Joecop » Mon May 09, 2016 11:48 pm

I believe the poorboy kit will work on a 1200. I used the diagram on this thread and went with a 3 inch diameter pulley I had a machine shop cut it pulley. I paid good money and the pulley is steel and heavy and I believe acts as a balance to boot. It runs smooth....



Post Reply