poorboy installation help!!


Information and questions on GL1200 Goldwings (1984-1987)
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crimsonwing
Posts: 85
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Motorcycle: 1984 GL1200I Interstate

poorboy installation help!!

Postby crimsonwing » Mon Apr 04, 2016 1:03 am



Hey all, I have the poorboy full kit coming in the mail soon, and i want to be as prepared for the installation as much as i can. Im gonna have a car mechanic and electrical engineer helping me so i don't want to waste their time, and since its a full kit, i'm hoping a lot of the work i have to do is minimal. that being said, How much do I have to do that the full kit doesn't do for me? I've read so much and seen videos but there is still a little confusion. Some people say i will need to purchase a new radiator hose. Do i really? and if so why? Also, none of the instructions i see say to grind the frame to be able to mount the alternator, do I or do I not? and if so how? do I really need a heatgun to deform my left fairing just so it can fit over alternator? do i need a new 50 amp fuse? lastly, some say you have to cut part of belt cover off and others say you have to drill a hole, which one? any pictures or videos you can link me to would be amazing or if you can take a quick video of your conversion i would love that too!! thanks!! :D



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twocams
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Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
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Re: poorboy installation help!!

Postby twocams » Mon Apr 04, 2016 10:32 am

Some things the kit wont do for you: Drain your radiator, take your upper and lower hoses off. Pull your timing belt covers off. You have to make the hole bigger where the 2 covers meet in the middle.Grind it, use your teeth. :? The radiator will be moved out at the bottom some to clear the new alt. belt. The hose at bottom becomes to short. I would replace both while your are there any way. Also the timing belts If not sure when done last. There maybe some grinding on the metal where one of the brackets mount. My alt. was already there when I got the bike. From what i have seen the radiator fan mounting may have to be modified some. Google poor boy alt. I think he has his own video. Or someone does about a 20 min. one? Using his kit. No you dont have to deform your LOWER fairing, you can just leave it off.

twocams

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Mon Apr 04, 2016 5:25 pm

thanks for the prompt response twocams, and oh man are you lucky for already having an alt on you wing!

Pope82
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Motorcycle: 1989 honda GL1500
1984 honda GL1200 aspencade
1982 yamaha virago xv750
2002 suzuki savage ls650(sold)

Re: poorboy installation help!!

Postby Pope82 » Tue Apr 05, 2016 6:27 pm

When you get your kit in the mail I would go to an auto parts store and have it bench tested for peace of mind. When my kit came I installed it and did not think I had any problems for the first day or two but then felt something was not right . When I had it bench tested it failed (I have bought brand new parts before that had a defect but I did not think of it until after I installed mine) . I did not want to deal with return shipping or anything so I bought a 89' Geo Metro alternator with a lifetime warranty , had it bench tested , modified it (grinding one ear off), and then had it bench tested again for peace of mind. Lessons learned I guess . napa 7733 will work for both the bottom and top hoses just cut it in half.

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Wed Apr 06, 2016 12:52 am

wow, thanks pope82! i didnt think of that, you just saved me from a lot of possible trouble haha

225orourke
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Location: Paris TN
Motorcycle: 1985 1200 limited edition

Re: poorboy installation help!!

Postby 225orourke » Wed Apr 06, 2016 5:18 am

When you get your kit can you post the determination of the pulley? If it's 5 inches or 6 inches and the offset also the shaft size please thanks Jay

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twocams
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Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Wed Apr 06, 2016 10:15 am

I bought a Napa 7733 hose, cut it to fit. But because the bottom of the radiator outlet and water pump outlet were no longer in line. And the 7733 was so straight mine would leak. So I had to get a hose with a somewhat bend in it. Most everyone has used the 7733 hose without problems. Maybe Im just to picky. :shock: just for information purposes only.

twocams

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Wed Apr 06, 2016 11:55 am

thanks guys, i will be posting soon

Pope82
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2002 suzuki savage ls650(sold)

Re: poorboy installation help!!

Postby Pope82 » Wed Apr 06, 2016 6:22 pm

This is what I got when my kit came (even though it is listed my kit did NOT have a inline fuse on the 10 ga. wire.) Hopefully this will help you too , 225orourke
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crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Thu Apr 07, 2016 5:11 am

I got the pulley on the crankshaft but two things, one i didnt use blue loctite. two, i didnt use any spacers. am i good to go? did any of you not use these and have a successful set up?

225orourke
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Re: poorboy installation help!!

Postby 225orourke » Thu Apr 07, 2016 5:14 am

Was it a 5 or 6 inch pulley. Please let me know. Thanks Jay

Pope82
Posts: 45
Joined: Mon Jul 20, 2015 2:45 am
Location: St.Augustine,Florida
Motorcycle: 1989 honda GL1500
1984 honda GL1200 aspencade
1982 yamaha virago xv750
2002 suzuki savage ls650(sold)

Re: poorboy installation help!!

Postby Pope82 » Thu Apr 07, 2016 5:12 pm

3.5 inch pulley and I just torqued the bolt to spec , I think 55 lbs. Of torque if I am remembering correctly. I made sure to use the loctite on the bolts for the radiator fan when I did mine so I did not have to pull the radiator and re tighten later

225orourke
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Re: poorboy installation help!!

Postby 225orourke » Thu Apr 07, 2016 5:17 pm

Thanks a bunch for the size. Jay

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Fri Apr 08, 2016 1:55 am

also when the original crankshaft bolt came out, the crankshaft moved, and of course along with the cam pulleys and belts. Im just a little paranoid so i need reassurance. that shouldn't be a problem right? i mean i cranked it over by hand over 5 times and everything lined up perfectly. so wouldn't that mean if the crankshaft moved after the belts were installed, everything would still be and move in correct timing? if not we have a problem. is it possible to turn the crankshaft without seeing the T1 mark move? i wouldnt imagine not since they are connected and essentially the same thing right?

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twocams
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Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Fri Apr 08, 2016 10:11 am

As long as the T1 is in the same place as it was when you started. It hasn't moved up or down 1/8 in. or something. Should be good to go.

twocams

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Fri Apr 08, 2016 12:36 pm

twocams wrote:As long as the T1 is in the same place as it was when you started. It hasn't moved up or down 1/8 in. or something. Should be good to go.

twocams


im sorry, im nit quite sure what you mean when you say before i started, before i started changing the timing belts or before i started putting the new crankshaft pulley bolt in? also, i currently cannot see the T1 mark, but like i said, that is because the whole set up moved as I put the new crankshaft pulley bolt in, im sure if i cranked it by hand again to where both cam pulleys face "up" at 12 o clock, the T1 will definately show up again. would that be fine? also im going to use a bit of super glue to get the timing covers back on right. any objections?

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twocams
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Location: Grants Pass, Oregon
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Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Fri Apr 08, 2016 6:27 pm

T1 should be in the window and cam gears should all be lined up with their marks when # 1 piston is at tdc (top dead center)on compression stroke. if I remember right there is a line cast into case where the T1 should be lined up with. As you turn the engine over at couple times everything should line up at some point (TDC). After new belts are on. I like super glue. not sure where U putting it.

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crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Fri Apr 08, 2016 7:44 pm

i will be putting locktite since i have tot ake it back out anyway. aslo can i crank it by hand after i install the pulley again?

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twocams
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Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Fri Apr 08, 2016 11:03 pm

Sure as long as the cam belts are on and tightened up.

twocams

Pope82
Posts: 45
Joined: Mon Jul 20, 2015 2:45 am
Location: St.Augustine,Florida
Motorcycle: 1989 honda GL1500
1984 honda GL1200 aspencade
1982 yamaha virago xv750
2002 suzuki savage ls650(sold)

Re: poorboy installation help!!

Postby Pope82 » Sat Apr 09, 2016 10:58 am

This link should give you all the info you need to do your timing belts correctly . http://www.goldwingfacts.com/1200timingbelts.htm

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twocams
Posts: 554
Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Sat Apr 09, 2016 11:29 am

That is a good how to, but if your going to do all that. Why not paint and clean things up? :?: I know ts a busy shop...bla bla bla.
Dont ever put your bike or car back together looking like that. :roll:
twocams

crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Sat Apr 09, 2016 4:49 pm

twocams wrote:That is a good how to, but if your going to do all that. Why not paint and clean things up? :?: I know ts a busy shop...bla bla bla.
Dont ever put your bike or car back together looking like that. :roll:
twocams


sorry to say twocams but i will be putting by bike together with little cleaning as well lol. I need it up and running asap before life goes from bad to worse

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twocams
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Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: poorboy installation help!!

Postby twocams » Sat Apr 09, 2016 6:46 pm

Ya theres always tomorrow. But you have nice weather almost yr around. I know, I worked at Camp Pendleton USMC for 2 yrs as a civilian. Then moved back to Oregon where I only have 34,600 people to dodge in town. :shock:

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crimsonwing
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Re: poorboy installation help!!

Postby crimsonwing » Sun Apr 10, 2016 12:20 pm

twocams wrote:Ya theres always tomorrow. But you have nice weather almost yr around. I know, I worked at Camp Pendleton USMC for 2 yrs as a civilian. Then moved back to Oregon where I only have 34,600 people to dodge in town. :shock:

twocams



ah, i see, so you would know. funny thing though is its actually raining right now and i still need to grind it bit more. frustrating, but if the rain subsides i think ill finish today! i just need help on the wiring. I don't understand where to place the new 50 amp fuse and 15 amp. i also got the 50 amp fuse breaker but it seems like i need some extra wiring that didn't come with the kit. any help? i aslo dont know how to unplug the original r/r and stator, i found this on another page "If your stator is indeed bad remove the voltage regulator and plug from the bike and use the switched terminal for your exciter terminal." do i need to do this? im not sure if stator is bad or r/r or both

crimsonwing
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Motorcycle: 1984 GL1200I Interstate

Re: poorboy installation help!!

Postby crimsonwing » Sun Apr 10, 2016 8:08 pm

new concern about the timing belts, two things. one, as i was installing the crank pulley, i cranked it a little faster than recommended and i was wondering if that can be bad even though the belts were already installed with the correct timing. also, can i start up my bike without the T1 showing in the viewing hole? Not to be confusing but again, it is already aligned, i was just wondering if the T1 by necessity has to be at the top to start. I guess im trying to ask if every time the engine is turned off, does it automatically reset to T1 at the top? or does it just stop wherever it stops?




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