Poor Boy vs Stator Replacement


Information and questions on GL1200 Goldwings (1984-1987)
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patbrandon1
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Poor Boy vs Stator Replacement

Post by patbrandon1 » Sat Jan 04, 2020 3:39 pm



I limped my 87 Interstate through the last half of the 2019 riding season without a working stator.

I added an extra small battery to the system and had it hooked up with the main battery, (I put it in the left pannier) and it worked well to increase some time for ride without charging. Didn't go on any long rides, and I also had a battery jump pack with me so I wouldn't get stranded. All of my lights and blinkers are LED, so the draw was minimal.

My question is this...
Would you put on a poor boy conversion or replace the stator?

In doing some research, it seems that the 1200s do have a problem with stator failure. And the output is less than adequate if one wanted to add anything such as heated grips etc. So with the possibility of another stator failure, and low output, I have been thinking of doing the poor boy.

Any of your experiences with this might prove useful before I make a final choice. I will probably start this project at the beginning of February.



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CrystalPistol
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Re: Poor Boy vs Stator Replacement

Post by CrystalPistol » Sat Jan 04, 2020 3:49 pm

Took a week of spare time after work a few hours, etc until supper. Took a piece of plywood cut to same size as engine bottom, added a smaller piece in center with round cut out to locate jack pad of my small floor jack dead center, a couple strips on other side to engage ribs, roll jack with one hand, balance engine with other. Set engine on wood blocks to work. Did a lot of cleaning, wax, etc too. I used Honda part, warrantied for life. I remember taking carbs loose as a unit, I tink I took them and left sitting on a freezer top, but some tie them up high. Put a new plug on too, but I soldered the connectors at the crimps, packed with dielectric grease. Was 1998, sold bike in 2019 … never another hiccup.
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patbrandon1
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1982 GL1100I (Crashed)
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Re: Poor Boy vs Stator Replacement

Post by patbrandon1 » Sat Jan 04, 2020 4:45 pm

CrystalPistol wrote:
Sat Jan 04, 2020 3:49 pm
Took a week of spare time after work a few hours, etc until supper. Took a piece of plywood cut to same size as engine bottom, added a smaller piece in center with round cut out to locate jack pad of my small floor jack dead center, a couple strips on other side to engage ribs, roll jack with one hand, balance engine with other. Set engine on wood blocks to work. Did a lot of cleaning, wax, etc too. I used Honda part, warrantied for life. I remember taking carbs loose as a unit, I tink I took them and left sitting on a freezer top, but some tie them up high. Put a new plug on too, but I soldered the connectors at the crimps, packed with dielectric grease. Was 1998, sold bike in 2019 … never another hiccup.
I am thinking that this might be the way to go. Do you remember where you got the new stator? And did you also replace your regulator/rectifier? I hear that even though they might pass the multi meter tests, they could still be bad, and perhaps attributed to the demise of the stator.

And what did you mean by "Put on a new plug too"? What plug?

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Rednaxs60
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Re: Poor Boy vs Stator Replacement

Post by Rednaxs60 » Sat Jan 04, 2020 5:10 pm

Have done the external alt mod on my '85 Limited Edition instead of a stator replacement. Either is good.

If you replace the stator, and have the back end off, do a clean of the sprague clutch while you are in there. The parts are inexpensive as well so a change out of the old parts is good.

A newer regulator such as a series type will also be beneficial. The newer shunt regulators with the Mosfet internal components is another option, and less expensive.

Good luck.
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CrystalPistol
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Re: Poor Boy vs Stator Replacement

Post by CrystalPistol » Sat Jan 04, 2020 5:46 pm

patbrandon1 wrote:
Sat Jan 04, 2020 4:45 pm
I am thinking that this might be the way to go. Do you remember where you got the new stator? And did you also replace your regulator/rectifier? I hear that even though they might pass the multi meter tests, they could still be bad, and perhaps attributed to the demise of the stator.

And what did you mean by "Put on a new plug too"? What plug?
I bought my stator from Schroeder's Honda in Hendersonville, NC. I think poorboy was in diapers then. It was 1998.
I never changed the reg/rec unit, but I did bypass it's plug there under the faux tank cover with three multi strand 12 ga yellow wires and spliced / soldered / and crimped a brass sleeve on each, then shrink wrapped them, then tape, and then a zip tie too. Just those three, the other several wires I left in plug. The new plug (Honda # 31105-ML8-305) I put on was down in front of battery, just three yellow wires. Mine was melted but Honda sold replacement kits. I know heat from high resistance melted it, but terminals had a tight grip so I soldered the crimps. I pulled each wire and soldered it at crimp to terminal and reassembled, packed with di-electric grease. I did that in 1998, the pic below was after I had put a new battery in years later as can be seen. Notice the terminals look great, no burning, no melting. I inspected the plug a few times, then re-wrapped it. Sold bike this past June.
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Ohara
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Re: Poor Boy vs Stator Replacement

Post by Ohara » Sun Jan 05, 2020 9:11 am

If your poor boy alternator dies, it can be fixed anywhere. If your stator dies anywhere you will have a problem. That being said, it is a tough choice. I agree pulling the motor yourself will be a great opportunity to clean check and fix many things. Good luck.

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AZgl1800
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Re: Poor Boy vs Stator Replacement

Post by AZgl1800 » Sun Jan 05, 2020 10:46 am

IF,
I owned a 4 cylinder and the stator went bye bye, that would be the end of stators for me, period.

I would just cut the 3 yellow wires, throw out all of the charging system wiring, and install the alternator on the front and be done with it forever.

as said, if the alternator fails somewhere, it can be fixed "right here" at the closest auto store.

if the stator fails anywhere, you are screwed until you figure out how to get back home, and go thru the song and dance to replace a bad system.... I have never, ever, felt like a system that imposes an Overload on the generator to keep it from overcharging the battery was ever a good idea.

my '51 Plymouth, at least, had a vibrating reed voltage regulator. Not a shunt.

.
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CrystalPistol
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Re: Poor Boy vs Stator Replacement

Post by CrystalPistol » Sun Jan 05, 2020 1:45 pm

Well, you've already learned one means to ride on with a failed stator. I always figured if I was far from home, I'd maybe get a U-haul home if need be … or buy a car battery at Walmart, etc, stick it in a saddle bag or cooler rack or even trunk and run some wire, 12 or 14 gauge would run the bike, jumper cables would let me start if I ever shut it off. The decision would be largely dependent on how far from home I was.

As it turned out, I just avoided stop lights and left my fog lights off (They were a pair of 37.5 watt sealed beam Unity fog lights, running them used 75 watts the reg/rec didn't have to ground).

When mine went out, it was not a total failure, I was on a ride I noticed that going through a town with multiple stop lights, it took a bit longer to get system voltage back up around 14 volts. When I bought the bike, one of my first mods was adding a Sun-Pro analog volt meter. I saw that It just stayed in the 12s for longer periods at highway speeds where as it had been building back up quickly. That was my clue, tests later at home confirmed it, one leg of the three was dead. I did finish the ride that day keeping a close eye on the meter. It would slowly build voltage back up as long as I kept RPMs up and stayed off brakes (lights). I didn't pull any fuses or headlight bulb, but I could have.

Stators …. even alternators have them. In the 1200 it's just inside a case at rear of motor. The bike spins a permanent magnet in a rotor past the windings (current output depends on how fast the magnet passes the windings, so a way to handle excess current is incorporated via shunt). Regular alternators pass a electro magnet rotor past their stator windings (current output is adjusted by varying current to the rotor). I think a large part of why the 1200 gets such bad press on the issue is the access to it. My older British bikes had stators, excess voltage or current went to ground through a Zener diode in a heat sink.

Was a time I collected stuff to do a poor-boy mod, got pulleys for three rib serpentine belt, got alternator too, but I never did it. Was gonna run it & rely on OEM as back up, but then it would have added more mass to speed up and would have added a pull to one side of front main bearing in engine.

If I were faced with the decision today, not sure which way I'd go. Don't know if Honda still has their stator, not sure of quality of aftermarket stators either? If I could feel I could get a good one, I'd probably replace the stator as I'm not likely to ride a 30+ year old MC across country … but in 1998 I had thoughts of riding a then 10+ year old MC virtually anywhere … While I did not then know of the "Poor Boy Mod" by name, I knew it was an option.
patbrandon1 wrote:
Sat Jan 04, 2020 3:39 pm
I limped my 87 Interstate through the last half of the 2019 riding season without a working stator.
… etc …
My question is this...
Would you put on a poor boy conversion or replace the stator?
… etc …
I know, not much help ….. Good luck.
Make Courtesy your "Code of the Road" …

… & Have a Safe Trip!
:)

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oldishwinger
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Motorcycle: 1986 GL1200 Aspencade

Re: Poor Boy vs Stator Replacement

Post by oldishwinger » Tue Jan 07, 2020 10:02 pm

After blowing the first stator, and another with an unknown fault in the rectifier, I went the route of a poor boy installation. That was 3 years ago, and the bike has never looked back since. in my humble opinion, best thing I did.

good luck

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Ohara
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Re: Poor Boy vs Stator Replacement

Post by Ohara » Wed Jan 08, 2020 5:22 am

Also with the Poor Boy you do not have to worry about running things like heated clothing or grips.

ejohnw
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Re: Poor Boy vs Stator Replacement

Post by ejohnw » Tue Jan 14, 2020 9:32 am

I replaced my stator about 3 years ago, It may not be fun pulling the motor but when you are done your bike is as original. My biggest problem with the poor boy, is leaving a unsealed hole in the front of the engine where moisture and road dirt are not meant to go. This has to have a negative effect on timing belt life and I wouldn't want to loose one of those bad boys.



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