Poorboy Pulley Options


Information and questions on GL1200 Goldwings (1984-1987)
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zosxavius
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Poorboy Pulley Options

Post by zosxavius »



Is there an off the shelf pulley that works without major modification?

Seems like the guy making kits isn't responding. It's time to probably start coming up with a new solution. I can easily figure out the rest, but finding a pulley that works ok is a challenge to me right now. Bore is 12mm correct? I ideally want something with three grooves to match an off the shelf Geo Metro alternator. I'm assuming it's best to also match the pulley size correct?


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DenverWinger
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Re: Poorboy Pulley Options

Post by DenverWinger »

zosxavius wrote: Sun Jun 27, 2021 7:40 pm I'm assuming it's best to also match the pulley size correct?
Alternator on a car has a much smaller pulley than the crank pulley. You should strive for same thing on the poorboy, otherwise charging at idle RPM will suffer.

Hence, the biggest crankshaft pulley that will fit.

Don't know what can be found off-the-shelf that will fit.
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Ohara
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Re: Poorboy Pulley Options

Post by Ohara »

3 to 4 inch diameter pulley will work. Mine is 4” from poor boy and it does the job just fine. I did a lot of looking and found the KRC 40150340 would work. Also MCS INDUSTRIAL #82223306 by Woods. There was another one from the UK that was an aluminum V pulley ( forget the company name right now but will check my records) The above pulley’s will get you going. I will add that this is dated information so hopefully you will find one. One of the members here has used a power steering pulley off a Honda Prelude. He may chime in with his information. Good luck with your search.
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

Ohara wrote: Mon Jun 28, 2021 7:35 am 3 to 4 inch diameter pulley will work. Mine is 4” from poor boy and it does the job just fine. I did a lot of looking and found the KRC 40150340 would work. Also MCS INDUSTRIAL #82223306 by Woods. There was another one from the UK that was an aluminum V pulley ( forget the company name right now but will check my records) The above pulley’s will get you going. I will add that this is dated information so hopefully you will find one. One of the members here has used a power steering pulley off a Honda Prelude. He may chime in with his information. Good luck with your search.
The KRC looks like a good candidate but would need a bushing. I saw that yesterday too in searching for info.

I see the Poorboy Pulley just came with a locking washer. What do I need to do to keep a pulley and bushing from spinning freely once installed?
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

DenverWinger wrote: Sun Jun 27, 2021 10:37 pm
zosxavius wrote: Sun Jun 27, 2021 7:40 pm I'm assuming it's best to also match the pulley size correct?
Alternator on a car has a much smaller pulley than the crank pulley. You should strive for same thing on the poorboy, otherwise charging at idle RPM will suffer.

Hence, the biggest crankshaft pulley that will fit.

Don't know what can be found off-the-shelf that will fit.
Thank you. That's helpful.
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

Ohara wrote: Mon Jun 28, 2021 7:35 am Also MCS INDUSTRIAL #82223306 by Woods.
I looked up the thread that had that one and the woods pulley is 1/2" bore. 12mm is .425 inches. So it would have to have a bushing made for a press fit. I think other one with a 12-->14mm bushing is probably the easy answer. All off the shelf.
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Ohara
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Re: Poorboy Pulley Options

Post by Ohara »

Usually the torque of the bolt will hold the pulley from spinning. Be sure to use blue lock tite on the bolt. Your new bolt will need to be 1” longer than the original crank shaft bolt. Really Don Pigot (Poor boy) kit does come with the best pulley. He can take a while to reply but I would not give up on him. Yes you can put it together your self, lots of folks have.
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Re: Poorboy Pulley Options

Post by Ohara »

Once you have completed your conversion you will have peace of mind not worrying about a dead stator when you are not close to home.
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Re: Poorboy Pulley Options

Post by Rambozo »

You can also get a pulley with a 3/8" bore then drill it out to 12mm. No bushing, or lathe required, just a drill press will do the job.
McMaster Carr has pulleys and dimensioned drawings of each one.
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Re: Poorboy Pulley Options

Post by Rednaxs60 »

Check the auto wreckers for an early model Honda Prelude - early '90s. Check for a power steering pump pulley. Found one for my installation back a few years.
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zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

Thank you all. I'm going to just get the MRC pulley and a bushing. $50. I actually don't want to wait 2-3 weeks just for parts here so I'm just going put this together myself. My bigger issue is that the bike was running damned hot on the way back and seems to be super low on coolant. I give up on trusting POs anymore really. I'm just glad I don't seem to have done any major damage here. Head gaskets seemed to have survived. It never got into the red, but it pegged close. It's an 87 interstate btw. I did pull over to cool off but it pegged like immediately again. It was also super hot. I'm going to flush the oil and coolant a couple times and see if that's all it is. Fan was coming on. Worst case, I've done a water pump before.
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Re: Poorboy Pulley Options

Post by Rambozo »

Unless you already ordered it, at the moment it is on backorder.
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

Rambozo wrote: Tue Jun 29, 2021 4:46 pm Unless you already ordered it, at the moment it is on backorder.
Amazon had a couple plus the bushings I need. Looks like it's about a week away.
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Re: Poorboy Pulley Options

Post by Rambozo »

Great. I was looking at MSC, I should have known Amazon would have it.
Do you have a way to fit the bushing to the pulley?
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Rambozo
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Re: Poorboy Pulley Options

Post by Rambozo »

zosxavius wrote: Mon Jun 28, 2021 10:01 am I looked up the thread that had that one and the woods pulley is 1/2" bore. 12mm is .425 inches. So it would have to have a bushing made for a press fit. I think other one with a 12-->14mm bushing is probably the easy answer. All off the shelf.
BTW 12mm = .472" and 14mm = .551"
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Re: Poorboy Pulley Options

Post by froche »

I used a pulley and had an adapter machined for it. It cheaper than making a new one from scratch!

mine was for V belt but enlarges the hole in the pulley and had an adapter that was interference fit pushed in with a little blue locktite. The adapter was made with a shaft extension so when assembled the entire pully/adapter had a shaft to correctly space the entire assembly just far enough past the timing belt covers.

it is cheaper because you only need a 1.25 or larger diameter piece of steel (or aluminum) to make the spacer, about 5 inches long, and that leaves plenty extra to mount in the jaws of the lathe. Then your puller just has be be turned to make it an interference fit!
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

I'm going to send back the MRC pulley and just snag a prelude pump. It fits directly. My current issue is that I have no idea how I can make these brackets without a drill press and welder. Currently asking around to see if someone can make them. I have drawings.
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Re: Poorboy Pulley Options

Post by Rednaxs60 »

I did my own brackets out of 1" angle without a drill press or welder. Put the pieces together with nuts and bolts, fitted to position, then went to local welding shop to have welded. Here's a pic of the finished brackets, these are version 3.0:


This is a pic of the lower bracket installed:


Good Luck.
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zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »



Well this became really frustrating. I don't know what I did wrong here but I'm finding it impossible to get this alternator in far enough to clear the lower fairing. I'm hitting the carbs in the back of the alternator body. I can't get a 31.5" belt to fit to save my life so I went to 32.5". Fits perfectly. Except it leaves my alternator vertical, the only position it will fit with the carbs and the lower curve in the fairing had no clearance at all. Yeah I know I can bend it to shape, but it would be radical. my alternator body is only 4" deep. I don't think I can get many much smaller. Nor can I move it forward to clear the carbs. I'm already just slightly out of line with the pulley plus I have literally no clearance to the crash bars. I'll post another picture from the side.
zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

From the back. No clearance at all. None. My battery post has to go to the inside too. Which puts it almost touching the carbs. Joy. On the outside it totally blocks the fairing. It's stupid long. And yeah I nicked my carbs a little trying to cut away a bit of the firewall. 🤬
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zosxavius
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Re: Poorboy Pulley Options

Post by zosxavius »

Ok. I figured this out. Took a lot of problem solving haha. I'll post a lengthy reply on what I used and what probably went wrong.


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