Alternator Conversion Video

[Quarteg]

Hey everyone. I just wanted to let people know that I completed the alternator conversion on my '86 GL1200a Aspencade.

As no video existed to show you step by step what to do, I created one. I don't show you how to unscrew nuts, bolts, screws or even how to grind stuff. I show you every step that is necessary from start to finish. (If you don't know how to unscrew things or grind stuff, you probably should have someone else do the job)

The video is 57 minutes long and can be found on Youtube at;

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Take a look when you get a chance and pass on this valuable info to whoever needs it.

Thanks goes out to: Don "Poorboy" Piggot for all his help during my project and to Don Guadagni for supplying the instructions. Pictures were helpful and step by step was pretty good. I got hung up in a couple place where Mr. Poorboy helped out and I explain those in the video.

Hope everyone enjoys the video and keep riding.

[WingAdmin]

This is a fantastic piece of work! I'm sure many people will benefit from it.

A quick note: There are no SAE fasteners on Honda motorcycles - they're all metric. So the Allen screws on the seat might fit (almost) with your SAE tools, but they are in fact metric sizes.

[Quarteg]

Good to note. Thank you sir.

[SteveB123]

52:18

17.7 volts at the battery! WTF!

[Quarteg]

If you can find a way to knock that down I will gladly hear it. I have seen some people suggest that 14.4 is good.

I researched last night to see what that can do to the bike. 50% of people said it will burn out the battery, the other 50% said that there is nothing wrong with that. Either way, I have no idea how to lower it.

[SteveB123]

What alternator are you using?

I'm in the first 50%. Overcharging will kill your battery; however, I'll bet your lights are crazy bright!

[Quarteg]

I don't know what year it is, but it is from an 89 - 93 Geo Metro 3 cylinder like the instructions say. I made sure to bring the instructions with. I don't know if maybe I have a wire hooked up wrong... I know I followed the directions but I am rechecking tonight to see if I missed something. I have only been up and running since Wednesday.

[Quarteg]

I should also note that I forgot to unplug the voltage regulator from the stator when I first tested it. Yesterday (Thursday) I was running about 16.5. I still think it is high, but I don't know what to do about it.

[SteveB123]

If this is an OEM replacement alt, it's a 3 wire.
If it's a street rod style, its a 1 wire.

[Quarteg]

There are 3 places for wires... I only used the bottom for the ignition. Should I use a wire on top or on the side? In either case, where do I go with that wire?

[SteveB123]

Sounds like the regulator is compensating for a voltage sensing issue.

[Quarteg]

I have no idea what that means....

Any suggestions on how to fix it or what to look for?

[Quarteg]

Problem fixed!!!

I put a new battery in my multimeter and I am now getting the proper readings!!!

[SteveB123]

Problem fixed!!!

I put a new battery in my multimeter and I am now getting the proper readings!!!

lol....what readings are you getting now?

[Quarteg]

12.3 on idle and 14.4 at 2000 rpms

[SteveB123]

12.3 on idle and 14.4 at 2000 rpms

I hate you. I have 12.3 at idle, 12.28 @3K (just checked after she's sat for 8 weeks on her side stand and charger. Oh my, that's smokey!!), and all three stator wires are "good to ground", so it discharges while not running.

Busy building a deck, so no time to muck about with the GW.

Did you buy your alt new, if so where? Link?

[Quarteg]

I purchased mine new at O'riely's Auto Parts. I also purchased (2) 6' wires at the same time. (1) 8 gauge and (1) 14 gauge and it cost me around $133.

One thing I did not put in the video that I should have was to also disconnect the harness for the stator regulator, but that is in the instructions.

I don't know what year the alternator is, I just know that I stayed in the parameters of 83 - 89 Geo Metro and they picked one for me. I am guessing that model is the same for each year.

[WingAdmin]

Sounds like the regulator is compensating for a voltage sensing issue.

I have no idea what that means....

Any suggestions on how to fix it or what to look for?

This means that the sense wire on the alternator is seeing low voltage. Usually this is due to old wiring, connectors or switches, introducing resistance. The sense wire is intended to monitor the voltage of the battery, and adjust alternator output to compensate. Therefore it should show the same voltage as the battery's positive terminal. If the alternator sense wire is sensing low voltage, it will boost its output in an attempt to "compensate."

Measure the voltage difference between the alternator sense wire and the battery positive terminal. Ideally, there should be no difference at all. The more difference, the higher over normal the output of the alternator will be.

[Quarteg]

Thanks for the heads up. I am happy it was just my multimeter that was at fault.

[nevada4419]

What a great video, I wish I would have had it when I did mine. I also had a very bad time reinstalling the radiator. If anyone needs it the bottom hose I used is Goodyear number 63027.

[dvgdn]

I agree it's a pretty slick conversion kit but beware; the alternator Poorboy sent me was shorted internally and he wouldn't make it good. I'm out $130.00 for a new alternator and $20.00 shipping to send the defective one back.

[Quarteg]

Interesting to hear. I purchased the basic kit, not because I thought something would be wrong with the alternator, but simply to save money.

Happy Riding!!!

[jamie f]

hi quarteg!great video on alternator conversion.was wondering if you had the part number of that 'basic kit' from poorboy.i just had stator and voltage regulator go out last saturday after only 500 miles and am not too enthused about pulling engine again.any info on part kit would be greatly appreciated.thanks Jamie

[dvgdn]

I do not have the number but it shouldn't be too hard to find contact info for Poorboy. I just Googled it if I remember correctly. Have the alternator checked before you install it; mine was shorted and I had problems getting Poorboy to make it right. PayPal reimbursed me the cost of a replacement alternator because Poorboy wouldn't.

[Sheilabob]

Question regarding the alternator conversion.
Friend of mine has a marine alternator small enough to fit the bike.
It is a one wire self exciting alternator, therefore only one wire connection from the alternator to the positive of the battery.
Would this be suitable should I decide to use it. Meaning disconnecting the three yellow wires from the stator and running one positive lead from alternator to battery.