Updated Poorboy Installation Instructions
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Go to the link below and click on "GM Alternator for GL1200 by Donald (Poorboy)Pigott "
<!-- m --><a class="postlink" href="http://bobsold.goldwingfacts.com/">http://bobsold.goldwingfacts.com/</a><!-- m --> although this shows the older 2" Pulley, Don provides a larger pulley with his kit now. Got Don and Vic's permission to post this. Please let me know if I can improve it. I appreciate ALL the help from a lot of people when I did my installation. Here we go . . . . ------------------------------------ Instructions for installing GM alternator on GL1200 by Donald (Poorboy) Pigott (updated for Kit use) External Alternator Conversion Questions or to get current Conversion Kit price, send email to <!-- e --><a href="mailto:don_pigott@yahoo.com">don_pigott@yahoo.com</a><!-- e --> or <!-- e --><a href="mailto:goldwinger1984@yahoo.com">goldwinger1984@yahoo.com</a><!-- e --> (if you click the address above, it {should } create an email addressed to Don. There is an underscore you can't see in the real email address:don_pigott@yahoo.com) Ordering PoorBoy Conversion Kit: * - - - Login to your PayPal Account (or contact Don for other payment plans) * - - - * - - - <!-- m --><a class="postlink" href="https://www.paypal.com/">https://www.paypal.com/</a><!-- m --> * - - - PayPal - Send Money Tab * - - - To:don_pigott@yahoo.com (EMAIL Address) * - - - Amount: (check with PoorBoy for specific price when you buy it) * - - - Currency: USD U.S. Dollars * - - - For: Goods * - - - CONTINUE * - - - Add Subject, Message * - - - Click Send Money button bottom of page * - - - DONE. (NOTE: (again) Don's email address contains an underscore:don_pigott@yahoo.com) After ordering the PoorBoy Kit you will need to get these parts: · Alternator from a 89-93 Geo Metro 3 cylinder o - - - - - - There are many Alternators you can use but the one pictured below is a known commodity. o - - - - - - Even when you go to the parts store, you may see different sizes and shapes. o - - - - - - Make SURE YOUR ALTERNATOR LOOKS LIKE THE ONE PICTURED BELOW With the new larger crank pulley it will take a different length belt. It needs to be 31.5" long. o - - - - - - · Wiring is 1 piece of 8ga AND 1 piece of 14ga both about 3' long. o - - - - - - Hi-end Auto Audio stores have wires (Meyer Emco / Circuit City / Best Buy) · 50 Amp Fuse for 8ga wire o - - - - - - Marine Stores have 12V 50 Amp Manual Reset Breakers (pic below) o - - - - - - Truck Stops, Audio and Auto Part Stores have Amp Holders and 50 Amp Fuses · 15 Amp Fuse for 14ga wire o - - - - - - Auto Parts stores have inline Amp Holders and Mini-fuses <!-- m --><a class="postlink" href="http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_Alternator-Worldwide_5848628-P_11_R|GRPALTSAMS_539232063___">http://shop.advanceautoparts.com/webapp ... 9232063___</a><!-- m --> Also, click the link below and look for the IMAGE icon <!-- m --><a class="postlink" href="http://www.densoaftermarket.com/catalog/catalog.php?part=altn&year=1995&make=GEO&model=METRO&engine_type=L3">http://www.densoaftermarket.com/catalog ... ne_type=L3</a><!-- m --> The parts listed above are needed for sure. Variations of those parts or other optional parts are listed in the text below Contents of Poorboy External Alternator Kit · Upper and lower Alternator mounting brackets with mounting bolts · Radiator mounting bracket extenders with spacers and nuts · Pulley and longer Crank bolt ALTERNATOR INSTALLATION Each installation is unique so you will have to tinker around for your bikeâs characteristics. Start by removing · Both fairing lowers, · Left horn, · Radiator, · Fan assembly & air duct on left side. When you are removing the radiator, pay close attention to the orientation of the lower fairing mounting pieces. That will make it easier to install later on . . . Might want to mark them with a grease pencil, right and left, and note where they fit in relation to the radiator and bushings. You'll be happy later . . . You will have to cut the brace out that the horn bracket is welded to. Grind the upper end flush with the flat part of the bracket, as there is a reinforcement plate to go there (pictured below). Be careful grinding to not bugger up the threads. You might want to put some other nuts on the threads to protect them when grinding. Also you are pretty darn close to the Carburetor. You might want to be careful to avoid the "custom" etching I did on mine :lol: :lol: - (IF by chance you need to repair something, JB Weld works GREAT!!!) Install the supplied reinforcement plate and original fairing mount. The original fairing mount goes under the reinforcement bracket this will keep the proper placement for fairing reinstall later. You need to grind the original brackets flat where they are under the new reinforcement. I replaced my Cam Belts using the parts in the cross reference chart on the Parts Locator Thread ( <!-- m --><a class="postlink" href="http://gl1200goldwings.com/viewtopic.php?t=162">http://gl1200goldwings.com/viewtopic.php?t=162</a><!-- m --> ). You are RIGHT there and can replace the belts for $25-30. Tricky posted some instructions on this but I could not find them to add the link. My belts were "loose" (55,000 miles) and the bike acted finicky when cold. MUCH better now. Your call what you want to do. Pretty easy to do. Remove the left engine to frame bolt just above the timing belt cover, inboard of the intake manifold. Install the lower mounting bracket using the engine to frame bolt. Trial fit the alternator (you will have to trim the alt. some) . You will have to put the left cover back on for this. NOTE: "Trimming" the alternator was removing the rear mounting lug in my case. I also ground off some casing material that would be close to the fairing cover to minimize the amount the cover will have to be "bubbled". When trimming the alternator, cover it so it does not get metal grinding inside. Tape works and go slow. With the alternator roughly in place it is time to install the crank pulley. Take the left cover back off and remove the crank bolt. You can use an impact wrench or put the bike in top gear and have someone step on the rear brake. Bolt uses standard threading; clockwise to tighten, counter-clockwise to loosen. Next you will cut the timing covers to fit around the new crank pulley stem. Just cut the timing covers enough so the pulley stem fits through the timing belt cover (the pulley fits completely OUTSIDE the timing belt covers). Go slow when cutting and you might as well polish the timing covers at this time . NOTE: Make sure the right timing cover (i.e. passenger side) is on and TIGHT, before proceeding to the next step. The right timing cover needs to be on and TIGHT to compress the rubber seal. This is important. BIG TIP - NOT TOO TIGHT!!! Trust me, its a long story, TIGHT but don't go crazy tightening it Check Torque specs or just use common sense. Tip it is a CAST block and the bolts receptacles CAN break off. Then it gets ugly :oops: :oops: :oops: Put the crank pulley on using the longer bolt . You will reuse the thick washer just under the bolt head & the larger thin washer(timming belt guide)behind the crank pulley. Install the crank bolt with âBLUEâ Locktite, NOT âredâ (Loctite 242 for example) Put the belt on and pull it tight. Pull the alternator up against the reinforcement plate. You will have to trim the front screw bracket that holds the fairing lower. This is the one under the new reinforcement bracket. Some people have found a SPOT for the removed horn. If you can bolt and connect the horn up in the general area it came from, go for it. The bottom of the radiator needs to be moved forward using the provided radiator extension bolts that screw on the original radiator-mounting studs (pictured below). You will have to remove the metal spacers that were on the rubber mounts for the new bolts to fit thru the lower radiator mounts. - - - The lower fairing mounting brackets need to be drilled to fit the new bolt size on the radiator extensions. NOTE: The mounting bracket for the fairing lowers is then installed on the extension behind the radiator rubber mounts behind the radiator (as it was before). When you disassemble the lower fairing brackets to drill them you might get confused on how they go back on (personally speaking). The brackets go on with the Square Notch pointing DOWN towards the floor and the fairing mount OUT. Thank God for the Clymer picture . . . .. The bottom hose will reach the engine, just loosen both clamps and wiggle it around a bit. Here is an optional item to consider. The factory hose WILL fit as stated above. I went to an auto parts store (AutoZone) with the existing lower hose and tried to find one with the "right curves". With the following hose, you will be able to cut a section out for the lower AND the piece left over looks like an exact fit for the top hose (but I did not install). Hose 3033 14-1973-6 M 63027 There was not a brand name but 3033 and 63027 were on the label 3 times and the bar code number was 0 37256 03793 1. NOTE: cut the lower hose to the needed length first, then see if the top fits. This information was also provided: Radiator Hose: (Cut in half to make 2 hoses)
85 & 93 Aspencade's
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#1
07-27-2007, 06:59 PM,
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Well done Bill. Very clear and comprehensive instructions.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com |
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#2
07-27-2007, 07:14 PM,
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admin Wrote:Well done Bill. Very clear and comprehensive instructions. Thanks Vic. I added some more info regarding Tricky's 50 Amp Manual Circuit breaker, brand name, model number / bar code. Also I found a radiator hose from AutoZone that works a bit better for the lower radiator hose if people wanted to pursue it. You don't need to replace the radiator hose as Don states, but if you wanted to spend $6 , , , , you could replace both the upper and lower hose while doing the conversion. Don't need to but . . . . optional
85 & 93 Aspencade's
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#3
07-28-2007, 07:25 PM,
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Just to clarify things Bill went in and added a great amount of needed detail to Don's original installation instructions and that's what I was thanking him for.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com |
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#4
07-29-2007, 09:08 AM,
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Great work Bill. Some of us have altered the original setup pretty drastically. I placed the fan on the front of the rad to get a lot more room behind the rad and installed a 5" pulley. That freaks out some but it works like a charm. :lol:
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#5
07-29-2007, 05:11 PM,
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sundance Wrote:Great work Bill. Some of us have altered the original setup pretty drastically. I placed the fan on the front of the rad to get a lot more room behind the rad and installed a 5" pulley. That freaks out some but it works like a charm. :lol:Bill thank you. I did read your post and like others thought it was very good. If you want I could post it at the end of the instructions as an optional item to consider. If so, please post where the info is in this format If you wanted to place the fan in front of the radiator, look at the information posted here: · GL1200 GOLD WINGS forum ( this forum ) ( <!-- m --><a class="postlink" href="http://gl1200goldwings.com/index.php">http://gl1200goldwings.com/index.php</a><!-- m --> ) · In the CHARGING SYSTEM AND CONVERSION ALTERNATORS section · In topic: WHAT TOPIC? · Look for this post by YOUR LOGIN NAME, dated weekday MONTH DD, 200X XX:XX a/pm Thanks. I think I read all your stuff regarding the conversions and realize MAN the people on this forum do some FINE work. I wish I had the time and skills to do what y'all do. Just happy to learn from it. Take care
85 & 93 Aspencade's
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#6
07-29-2007, 05:31 PM,
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Updated to use Don's new email address: <!-- e --><a href="mailto:don_pigott@yahoo.com">don_pigott@yahoo.com</a><!-- e -->
Old email was: <!-- e --><a href="mailto:poorboy57@juno.com">poorboy57@juno.com</a><!-- e --> PayPal should work with the new email address I hear. Take care
85 & 93 Aspencade's
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#7
07-30-2007, 08:55 AM,
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I did not have to heat and bend my fairing. I have at least 2 inches of room!!
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#8
08-04-2007, 04:21 AM,
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Even with my mini alternator I still had to create room behind the fairing. I'd love to see your setup and how you got the extra space none of us seem to have. (I'm always looking for a better way)
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#9
08-04-2007, 08:03 AM,
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BTW Bill, I'll send you the stuff on the pulley and front fan mount if you want it. I was going to send it to you via email but there isn't one in your profile. If you like shoot me an email and I'll send it in a reply.
<!-- e --><a href="mailto:bill@billfarrar.com">bill@billfarrar.com</a><!-- e --> |
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#10
08-04-2007, 08:06 AM,
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Bill,
One correction my new email address is don_pigott, the way you have is listed it looks like don pigott. Poorboy |
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#11
08-09-2007, 06:51 PM,
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Just FYI, one of my chapter members is working on getting me a fan set up from some kind of delivery vehicle he works on at his place of employment. He says they have good CFM and are quite a bit thinner than our stock Honda fans. Soon as I get one and confirm they will work for the conversions I will post more info. Perhaps even start selling kits or make a deal with poor boy to include them with his kit. :wink:
John McFarland
Chapter Director GWRRA FL2-W member 367388 |
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#12
08-10-2007, 06:56 AM,
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That would be a big help John. Looking forward to seeing what you come up with.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com |
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#13
08-10-2007, 09:53 AM,
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joseph038 Wrote:I did not have to heat and bend my fairing. I have at least 2 inches of room!!The embarrassing thing :oops: . . . I installed the conversion a LONG time ago (3-4 weeks) and did not finish putting it together. Been too HOT, been on vacation and had a '93 Aspencade to tide me over . . . . Hopefully I'll get to it and see if I have to bubble or not . . . . I did take off a pretty good size of the alternator case, as much as I could and still have metal left. Hopefully I'll get back at it tomorrow . . . . but I haven't ridden in a week (vacation), maybe tomorrow night . . . . :lol:
85 & 93 Aspencade's
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#14
08-11-2007, 07:26 PM,
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sundance Wrote:BTW Bill, I'll send you the stuff on the pulley and front fan mount if you want it. I was going to send it to you via email but there isn't one in your profile. If you like shoot me an email and I'll send it in a reply.YOU GOT MAIL (and I updated my profile. If you can or cannot see my email address now, I'd aprpeciate letting me know one way or the other. TANKS.)
85 & 93 Aspencade's
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#15
08-11-2007, 07:41 PM,
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