poor boy alt. conversion video


Information and questions on GL1100 Goldwings (1980-1983)
  • Sponsored Links
User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

poor boy alt. conversion video

Postby roadwanderer2 » Sun Nov 02, 2014 7:52 am



I have a question to ask....I just finished watching a video of how someone did a alt. conversion on a GL1200, and I was wondering......does the same process for this GL1200 work on the GL1100? although it was very detailed and informative, the person didn't say whether or not it was also applicable for the GL1100. also should an external voltage meter be installed onto the bike fairing somewhere if the "onboard" meter isn't working?

by the way, I've started repainting my nimbus grey bike to the diamond green flare poly I was talking about in my last posting. I've repainted both side covers and the entire fax tank shelter, and im now in the process of repainting the trunk. I'll post new pics once the trunk is finished so you can see the progress I've made.

stuart, a.k.a. roadwanderer2.



User avatar
RBGERSON
Posts: 2612
Joined: Tue Mar 09, 2010 7:57 am
Location: SCOTTSDALE, AZ
Motorcycle: 98 SE GL 1500
had every year from 75 to 83

Re: poor boy alt. conversion video

Postby RBGERSON » Sun Nov 02, 2014 8:43 am

Should be but w/o seeing the video hard to say..drill and hole int he front covers, add a pulley, hang an alternator off the side and wire it up..lining it up so the pulley runs true is the hard part..making brackets the right size is key
HAD LOTS OF GOLDWING 75-83
NOW INTO 1500'S..RIDING A 1998 SE

FAIR WINDS,
RB

User avatar
RoadRogue
Posts: 1913
Joined: Sun Jun 06, 2010 10:51 pm
Location: Castlegar BC, Canada
Motorcycle: 1997 1500SE

Re: poor boy alt. conversion video

Postby RoadRogue » Sun Nov 02, 2014 2:30 pm

Here is a link to answer your question about the poorboy conversion on a 1100 viewtopic.php?f=11&t=14362
It works well, ask me how I know.............. 8-)

p.s. a digital volt meter is always a good idea 8-)
Ride safe, Todd
Over night campers welcome

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Sun Nov 02, 2014 5:13 pm

hey guys,

here's a link to the "poorboy" conversion video.............

it IS really worth watching from beginning to end.

and heres a few more pics of the bike repaint. its coming along quite nicely especially using spray paint from a can. eventually everything I've painted will be sanded back down to the bare plastic, (since the darker color will show thru the green paint), and started over using REAL automotive paint from a REAL spray gun in the same exact color. I've been thinking about what color pin stripe to use, and since the badges and emblems are done in gold, im gonna go with gold pin stripes as well. once the gold pinstripes are back on the bike, it'll look much better. the next new seat cover will be done in black with gold stitching and gold piping and it will have the Goldwing name and the bird done in gold to set everything off with coordinated matching colors.

stuart, a.k.a roadwanderer2.
Attachments

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Sun Nov 02, 2014 7:14 pm

hey tod,

very nice pics of your conversion. its good to see everything up close with the arrows and measurements. im gonna keep that complete posting saved for future reference in case I have to do a conversion on my GL1100.

stuart, a.k.a. roadwanderer2.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Tue Nov 04, 2014 6:35 am

RoadRogue wrote:p.s. a digital volt meter is always a good idea 8-)


ok guys, here's a question for ya's. after installing an external volt meter,(sunpro), onto my bike, and I assume its working correctly, why would the bike draw power even when the ignition switch is off? for some reason the bike is drawing constant power from somewhere even with the bike shut off. I used a test light and put it into the voltage regulator wires and a few other wires and its drawing power with the bike shut off and I don't know where its coming from. what do I have to do to find the source of the power drain. any ideas?

to make sure the bike is off, I installed a 35 amp interrupter toggle switch using 14 gauge wire directly to the battery to make sure it shuts down the bikes power completely. it serves 2 functions, it shuts all the power off, and its also an anti theft device. I have it mounted where no one but me can access it.

stuart.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Tue Nov 04, 2014 8:41 am

ok guys, I ran into a problem with the wiring on the toggle switch. apparently the 14 gauge wire I put on isn't heavy enough to work. I went out to my garage to fire up the bike, put the switch in the "on" position, pressed the starter button and the wire that I have running from the switch to the + side of the battery melted and the bike acted like it had a dead battery. after I disconnected the switch and hooked the factory + cable back onto the battery, the bike started right up. what would be the correct gauge wire I should be using? should I be using the really heavy wire that has only one single thick strand? what gauge wire is that, 8, 10 or 12.

stuart.

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Tue Nov 04, 2014 12:07 pm

roadwanderer2 wrote:ok guys, here's a question for ya's. after installing an external volt meter,(sunpro), onto my bike, and I assume its working correctly, why would the bike draw power even when the ignition switch is off? for some reason the bike is drawing constant power from somewhere even with the bike shut off. I used a test light and put it into the voltage regulator wires and a few other wires and its drawing power with the bike shut off and I don't know where its coming from. what do I have to do to find the source of the power drain. any ideas?

to make sure the bike is off, I installed a 35 amp interrupter toggle switch using 14 gauge wire directly to the battery to make sure it shuts down the bikes power completely. it serves 2 functions, it shuts all the power off, and its also an anti theft device. I have it mounted where no one but me can access it.


Start by pulling all of your fuses. Plug each one in one at a time to see if one of them causes the parasite draw. That will give you at least a push in the right direction as to the cause of the draw.

If the draw is coming from the regulator itself, try disconnecting its sense wire and see if it continues.

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Tue Nov 04, 2014 12:16 pm

roadwanderer2 wrote:ok guys, I ran into a problem with the wiring on the toggle switch. apparently the 14 gauge wire I put on isn't heavy enough to work. I went out to my garage to fire up the bike, put the switch in the "on" position, pressed the starter button and the wire that I have running from the switch to the + side of the battery melted and the bike acted like it had a dead battery. after I disconnected the switch and hooked the factory + cable back onto the battery, the bike started right up. what would be the correct gauge wire I should be using? should I be using the really heavy wire that has only one single thick strand? what gauge wire is that, 8, 10 or 12.


14 gauge is nowhere near big enough for a battery cable (as you have discovered). Neither is a 35 amp swtich. That's fine for switching CHARGING power (assuming your alternator is not going to ever produce more than that), but your starter motor can pull well over a hundred amps - which is likely why your 14 gauge wire melted.

You need more like a 6 or 4 gauge wire to do what you're doing, as well as a switching mechanism that can handle that kind of current, like a purpose-built battery disconnect switch:

http://www.amazon.com/Battery-Disconnec ... ingdocs-20

The wire should also be stranded (not solid) - solid core wires will crack/break from the stress of vibration over time. Solid core is fine for house wiring that never moves, but not for motorcycles.

Rather than try to interrupt the battery, you would be better off finding the cause of your parasite draw and fix that.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Tue Nov 04, 2014 2:12 pm

hey wingadmin:

the wire im using IS an 8 gauge stranded wire, (see photo 2), not one solid wire as I might have mentioned in my last posting. the way I have the wire looped, its not going to move. I took a look at that battery disconnect switch, the only problem with that is where would I mount something that large. the switch I put on is mounted under the false tank shelter,(see 1st and 3rd photo), where I drilled a small hole in left side top of the air breather cover and put the switch into which is easy for me to get to. anything larger than that I COULD possibly mount that inside the saddlebag. as for the regulator, which wire is the "sense" wire?. this regulator has an 8 pin plug on it 2 red wires, 1 black wire, 3 yellow wires and 2 green wires, (see photo 5). as for the fuses, (see photo 4), I removed all of them and started to put them back in one at a time, and it seems that a few of them cause a power draw when the key is in the "off" position so I don't know where to start with that idea. the only things I can think about doing is install that battery shut off switch, keep using the toggle switch I have on it now, or make sure that when I shut the bike off, I press down on the ignition switch to stop all the bikes power. as long as I can see my volt meter go to 0 after I push down on the ignition key or use the toggle switch, I know the bike's power is completely off. I don't have the expertise to do what might have to be done to trace all of the bike's wiring system.

stuart.
Attachments

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Wed Nov 05, 2014 9:15 am

8 gauge wire is going to limit your current draw to 70 amps or so, not enough to properly power a starter.

The sense wire on the regulator is the black wire. Does power draw continue when it is disconnected?

Which fuses cause power draw when the bike is off?

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Wed Nov 05, 2014 10:31 am

hey wingadmin:

when you say disconnect the sense wire, do you mean unplug the entire voltage regulator harness connector? as for the fuses, I'll have to read what it says on the fuse block as to what the fuses are for. I cant do that right now because im going to go see my mother in law at the rehab center. she fell this past September and broke her femur bone just below where the ball connects to the hip socket in her left leg and her dr. had to implant a rod connecting the 2 broken bones together and she's been healing quite nicely and should be home in another 2 weeks just in time for thanksgiving.

when I get home I'll check that out. as for the toggle switch I put in, even though I had the heavy gauge wire, its still making the starter drag so I disconnected it and put the battery cable back onto the battery and im remembering keep my eye on my volt meter and to push down on the ignition key to make sure the bikes power is turned off. until I figure out what's causing the power drain that's how im gonna have to do it, but I will check what the fuses are for and make a note of it and let you know about those and about the regulator harness wires.

stuart.

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Wed Nov 05, 2014 12:40 pm

roadwanderer2 wrote:hey wingadmin:

when you say disconnect the sense wire, do you mean unplug the entire voltage regulator harness connector? as for the fuses, I'll have to read what it says on the fuse block as to what the fuses are for. I cant do that right now because im going to go see my mother in law at the rehab center. she fell this past September and broke her femur bone just below where the ball connects to the hip socket in her left leg and her dr. had to implant a rod connecting the 2 broken bones together and she's been healing quite nicely and should be home in another 2 weeks just in time for thanksgiving.

when I get home I'll check that out. as for the toggle switch I put in, even though I had the heavy gauge wire, its still making the starter drag so I disconnected it and put the battery cable back onto the battery and im remembering keep my eye on my volt meter and to push down on the ignition key to make sure the bikes power is turned off. until I figure out what's causing the power drain that's how im gonna have to do it, but I will check what the fuses are for and make a note of it and let you know about those and about the regulator harness wires.

stuart.



Actually, now that I think about it, go ahead and disconnect the regulator entirely and see if your voltage drain goes away.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Wed Nov 05, 2014 7:56 pm

hey wingadmin:

sorry for the long delay but I only got home around 6pm and my new rear coil over shocks were sitting on my front porch waiting for me, so I put them on and just finished up a little while ago. they are the stock length with 5 adjustment settings. no more worrying about putting air in the shocks. that makes me :D . boy I'll tell ya, im glad I bought an air compressor,(15gal/250psi), and new air tools. it made the job so much easer to do. got a new 1/2" drive air gun, 3/8" air ratchet and a 1/4" air ratchet. it took me a little while longer to get finished, I accidently crossed the signal wires for the rear turn signals :oops: so I had to take the saddlebags back off and reconnect the wires. right now im exhausted, I'll deal with the electrical problem tomorrow. I'll unplug the voltage regulator from the outlet side and see what that does. if that don't do it, I'll disconnect it from the inlet side and see what that does. in any event, i'll figure it out....eventually lol.

stuart.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Thu Nov 06, 2014 8:57 am

good morning ppl's.

ok, here's what I found out with the power draw. wingadmin, I did what you suggested about disconnecting the voltage regulator harness. I turned the ignition switch to the "on" position, turned it back off, disconnected the voltage regulator harness from the outgoing side and saw that it was still drawing power, so I removed each fuse one at a time, and the power draw is coming from the "acc" fuse. now, I pulled the fuse out and tried to fire up the bike and it did start up, but, my volt meter stopped working. so I put the fuse back in, then I did something else, I disconnected the ignition switch harness and the power draw stopped, infact, it shut all the bike's power off. im wondering if there's a short in my ignition switch because if I push down on the key after I shut the bike off, the power to the "acc" fuse stops.

stuart.

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Thu Nov 06, 2014 11:23 am

Ok, that tells us a couple of things. First off, the ACC circuit should not have any power going to it when the bike is turned off. The only way this can occur is if something is wrong with the ignition switch.

This theory is reinforced by the fact that pressing down on the ignition switch causes the parasite draw to the ACC circuit to shut off. So it looks like that's going to be your problem - possibly carbon or build up inside the switch contact itself causing it to conduct power when it is off.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Thu Nov 06, 2014 11:45 am

hey wingadmin:

ok, now that we have it isolated to the ignition switch, would you recommend taking the switch apart to clean it with the spray wire contact cleaner I have, or do the easer thing and replace the entire switch.

stuart.

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: poor boy alt. conversion video

Postby WingAdmin » Thu Nov 06, 2014 12:05 pm

roadwanderer2 wrote:hey wingadmin:

ok, now that we have it isolated to the ignition switch, would you recommend taking the switch apart to clean it with the spray wire contact cleaner I have, or do the easer thing and replace the entire switch.

stuart.


I would be inclined to try cleaning what you have first - any switch you find on eBay or wherever will be used, and might have the exact same issues.

User avatar
roadwanderer2
Posts: 4108
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: poor boy alt. conversion video

Postby roadwanderer2 » Thu Nov 06, 2014 2:43 pm

your right about the switch being used. I got this one used, but for a cheap price WITH the original key. the problem I now face is if I take the switch apart, are there any tiny springs inside that might fly out once I open it up. if that happens and they do go flying, im screwed, I'll never find them and wind up replacing the switch anyway. it was a nightmare putting this switch in. it took me about an hour and a half to do it not having done it before. when I got this bike the ignition switch wasn't even there. the PO took a regular car ignition switch, cut the wires, cut a hole on the right side of the faring and shoved it in and left it like that. it looked absolutely ridiculous. that's when I decided to get a switch that belonged on the bike. I don't know if this has been going on since I put the switch in, but I remember one time I locked the steering on the bike and the next morning when I out to start it up, (this was before I had the volt meter connected), the battery was dead not knowing that the switch might have been at fault because I never locked the steering after that. who knows, this might have been going on ever since I installed this switch 6 months ago.

stuart.




Return to “GL1100 Information & Questions”




Who is online

Users browsing this forum: Brandwatch [Bot] and 1 guest