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POORBOY KIT AVAILABLE HERE
Dan, if you were to go look around on this site you will find that several members are successfully using a larger crankshaft pulley to speed up the alternator. You just need to reposition the alternator to accomodate the larger pulley's new position. Those members are quite pleased with the difference in the charging performance with the larger pulley. Either way, small or big pulley, Poorboy's kit is a true blessing to the guy with a 1200 with a blown stator.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#16 07-13-2007, 11:39 AM,
Yes I've looked over the site.

I had a 4" pulley made for mine by using TN's spec's.
It works perfectly on my 1100.
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#17 07-13-2007, 11:47 AM,
How about a link to some pictures of yours Dan. I'm amazed that you got the alternator inside your 1100. It's a tight fit.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#18 07-13-2007, 11:59 AM,
dan filipi Wrote:Yes I've looked over the site.

I had a 4" pulley made for mine by using TN's spec's.
It works perfectly on my 1100.

****************************************************

How much did the pulley cost you?
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#19 07-13-2007, 12:00 PM,
Doug Wrote:Vic, What is the bore and key on the new pulley? Is it a Set screwed woodruf key,straight key, etc.,? Just Curious.
The timing belt pulley bolt is 12mm
The only stupid questions are the one's that are not asked.

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#20 07-13-2007, 12:17 PM,
It definately is a tight fit.
The left lower has to flex a bit to go back on.

I think I got lucky in finding a Denso which I think is smaller than most of the small Denso's.
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#21 07-13-2007, 12:31 PM,
Did I miss a print listed somewhere? We have our own machine shop at work and boss doesn't mind us working on stuff as long as our work is done. Being in the Ice Cream business, demands a lot of finessing parts and mods to make the new packaging work. It's usually stainless to boot.
Modifying a pulley shouldn't be a big deal or expensive for that matter if one has a print Big Grin Is it a typical v-belt or simular to the timing(power) cog belt? (Thanks Tricky for the earlier info) We have actually fabricated pulleys with screwed on/bolt on faces, for tight applications. Whew...I didn't realize this post goes all the way back to February! Talk about long conversations Confusedhock:
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#22 07-13-2007, 01:42 PM,
At Vic's request, I posted some pictures and the steps I took to install an external alternator on my 1100 a few months ago.

Read all the way thru because I made some changes and updates along the way to fine tune the installation as well as the web page.
(The web page I'll probably scrap and re-do someday)

Go to my start page then click on "My alternator conversion"
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#23 07-13-2007, 02:30 PM,
Thanks Dan. It just shows that the impossible is possible and I had to see it to believe it. Well done and great job.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#24 07-13-2007, 05:32 PM,
Vic, you asked how much I paid for the pulley.

Well.......alot!

Suffice it to say that the machinist said he could lower the price to $70 each if I ordered ten of them!
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#25 07-13-2007, 06:00 PM,
Great job on the conversion Dan, thanks for documenting it for us. It's nice when someone blazes the trail for others to followSmile


We have an old Italian machinist....he works for very little...Provide the part and twenty bucks....he'll do it. He's overbored a couple of things in the beginning, better now, and he takes FOREVER!!!!! Not a good welder though.



12mm X 1.25 pitch X 60mm long bolt



I can get you that bolt if you need it Smile We have them in stainless, i'll check to see if they are fully threaded(me thinks they are)Smile
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#26 07-13-2007, 06:10 PM,
dan filipi Wrote:Vic, you asked how much I paid for the pulley.

Well.......alot!

Suffice it to say that the machinist said he could lower the price to $70 each if I ordered ten of them!

******************************************************

That's not bad. I was quoted $100. on special case hardened aluminum pulleys one at a time. A lot of machining is involved. There's something very attractive about that old Italian price but I'd want to be sure that it's straight.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#27 07-13-2007, 06:31 PM,
Remember to use a thread locking silicon substance when you put the crank bolt back in.
Ask me how I know!!!!
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#28 07-20-2007, 08:54 AM,
And never use the red thread locking substance.
Ed (Vic) Belanger - 1954-2015
Founder of gl1200goldwings.com

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#29 07-20-2007, 10:43 AM,
I used the blue threadlocker on the first pulley.
Later when I removed the crank bolt to put the new pulley on, it took about 4 "impacts" with the air impact then spun off.

Seems good and aint gonna come loose, right?
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#30 07-20-2007, 02:45 PM,


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