GL 1200 alternator conversion


Information and questions on GL1200 Goldwings (1984-1987)
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jamie f
Posts: 80
Joined: Fri Oct 03, 2014 7:29 pm
Location: lodi wi
Motorcycle: 1986 GL1200 Aspencade, 1982 GS 850L,,wife's bike, 1981 GS1100E,sold,,Latest addition 1994 GL 1500 Aspencade.

GL 1200 alternator conversion

Postby jamie f » Thu Jul 23, 2015 7:57 pm



Well,it's started.Decided on going with alternator conversion.Got a pretty good start today after work.Removed lower left fairing,cut out tube as per video instructions,installed plate and made adjuster bracket to mount to left front motor mount.Ordered alternator for a Geo Metre 3 cylinder.Then I proceded to shrink tube/deadhead stator wires individually then taped them up nice and neat.Also shrink tube/deadhead 3 yellow wires from bike harness individually and taped them up and back to harness out of the way.
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Ready to cut out tube
Ready to cut out tube
Cut cleaned up
Cut cleaned up
Upper mounting plate area all cleaned up
Upper mounting plate area all cleaned up
Fabricate and install upper mounting plate.Will weld on alternator mount when "mocking up" when alternator arrives
Fabricate and install upper mounting plate.Will weld on alternator mount when "mocking up" when alternator arrives
Bike harness shrink tube/deadhead
Bike harness shrink tube/deadhead
Stator harness shrink tube/deadhead
Stator harness shrink tube/deadhead
Bike harness all taped up nice and neat back to harness
Bike harness all taped up nice and neat back to harness
Lower alternator mounting bracket,will cut slot for adjustment when "mocking up"
Lower alternator mounting bracket,will cut slot for adjustment when "mocking up"



User avatar
jamie f
Posts: 80
Joined: Fri Oct 03, 2014 7:29 pm
Location: lodi wi
Motorcycle: 1986 GL1200 Aspencade, 1982 GS 850L,,wife's bike, 1981 GS1100E,sold,,Latest addition 1994 GL 1500 Aspencade.

Re: GL 1200 alternator conversion

Postby jamie f » Fri Jul 24, 2015 5:43 pm

Had the day off today so I ran around gathering up parts to finish up the alternator conversion.Started off with picking up alternator and belt,then fabbing up alternator upper mount bracket.Then on to lower bracket and drive pulley.Could only get a pulley off an old denso alternator so it's a 1 to 1 ratio to alternator.Had to drill out front cover to put fabricated pulley in place.That was fun re-installing timing cover,gasket was a pain.Decided to run it off the left cam with a grade 8 bolt and red loctite.At idle charges 12.1 volts,at 2500 it charges 13.6 volts.Since I don't do alot of night driving,I think this will work just fine for me.Other option is to buy a power steering pulley for a geo metro, (4 1/2" diameter) and fabricate to bolt to cam,giving it about a 2-1 ratio which would charge better at low rpm's,and with brake on won't dim the lights at idle.Anyway it's back on the road and I couldn't be happier.Did this whole project in about 4 hours(besides research on this forum) for about $200.00,,Here is the final picture,keep in mind that left lower fairing was damaged anyway,so I didn't feel bad about cutting it.Thank you Goldwing Docs for all the information on this site.Without it,I probably would have given up.
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User avatar
jamie f
Posts: 80
Joined: Fri Oct 03, 2014 7:29 pm
Location: lodi wi
Motorcycle: 1986 GL1200 Aspencade, 1982 GS 850L,,wife's bike, 1981 GS1100E,sold,,Latest addition 1994 GL 1500 Aspencade.

Re: GL 1200 alternator conversion

Postby jamie f » Sat Jul 09, 2016 7:49 pm

Update,decided to change up my conversion and run it off the crank pulley.After modifying radiator mounts and lower hose,its back up and running.Now to get a left lower side cover and hide alternator.Also have to get new left timing belt cover,has hole in it from initial conversion.
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ddrichard
Posts: 16
Joined: Sat Nov 05, 2011 3:21 pm
Location: Canada
Motorcycle: 1986 gl1200a aspencade

Re: GL 1200 alternator conversion

Postby ddrichard » Wed Aug 10, 2016 4:50 pm

Hello great job on the conversion, I wonder if one of those rubber plugs would fit in the hole so you would not have to replace the cover. I did my conversion in 2012 and it is still going strong. Keep up the good work.... p.s make sure you have enough room to change belt on side of road if you ever need to

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Rednaxs60
Posts: 721
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: GL 1200 alternator conversion

Postby Rednaxs60 » Wed Aug 10, 2016 5:56 pm

Excellent job! The pulley from an '89 prelude power steering pump fits a 12 mm bolt exactly - bit of a friction fit. It is approximately 4". I used it on mine, works well.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

CrystalPistol
Posts: 257
Joined: Wed Mar 10, 2010 9:07 pm
Location: Shenandoah Valley of Virginia
Motorcycle: 1985 GL1200A
1997 GL1500SE Lehman Trike

Re: GL 1200 alternator conversion

Postby CrystalPistol » Wed Aug 10, 2016 8:17 pm

Rednaxs60 wrote:Excellent job! The pulley from an '89 prelude power steering pump fits a 12 mm bolt exactly - bit of a friction fit. It is approximately 4". I used it on mine, works well.

Good to know! 8-)


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