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POORBOY KIT AVAILABLE HERE
Hi All,
I emailed Don and he wrote back that he is no longer selling the kits.
Can anyone point me to an alternative kit or the best source of information on putting together an alternator conversion myself for my bike?
The crank pulley seems to be one part that is hard to get. From what I have read a 1989 Honda Prelude pulley is the one to get but is unavailable from Honda.
It seems that a Geo Metro OEM Nippon Denso alternator is one that is recommended as some have had trouble with the regulator rectifier in off brand alternators.
I like the idea of the kit that Don used to offer but will work on piecing together my own set up if a kit is no longer available.
My local auto salvage yard told me they don’t have either part available and that the did not know where I could find them because cars from before 2000 are routinely just crushed and hot held by salvage yards.
After a recent trip on my 1985 GL1200 I would like to convert to an alternator.
Any help pointing me in the right direction would be appreciated.

Thank you,
rube
Reply
#106 10-19-2021, 05:59 AM,
Hi,
I don’t imagine there are too many folks still looking to put an alternator conversion on a GL1200 besides me.
I tried upgrading the stock system with a series regulator and upgraded wiring, but I think the old stator is giving up.
So, I either buy a different wing or put an alternator on mine. I think I have read every thread on the topic and am now gathering parts.
So I wanted to answer my question above about pulleys.
Finding the pulleys has been frustrating, but I think I have them (on order) and wanted to post the info on the off chance that someone else was having the same problem I was in finding pulleys that work.
(This is cross posted at another site)

Pulley options I found.

V-belt
For the crank
V-belt pulley (A profile or 1/2 in wide belt) with 12 mm bore
https://www.rdgtools.co.uk/cgi-bin/sh00 ... ml#SID=585
By report this one bolts right up to the crank with a m12x1.25x60 bolt.

My alternator (Chevy mini from DB Electrical PN 400-52014) came with a 3/8 inch width v-belt pulley mounted on a 15mm alternator shaft.
To match the 1/2 in width crank pulley above….

Denso Alternator Pulley 1/2″ Belt Width X 2.717″ OD x 15mm ID

https://brillman.com/product/denso-alte ... x-15mm-id/


Micro-grove pulleys
For the crank
(I have not been able to find a power steering pump from a 1989 Honda Prelude)

Micro-groove, 3-rib pulley,
Not sure on the shaft bore on this one but recommended in one poor boy write up I read

Part # KRC 40140300

https://www.krcpower.com/ecommerce/repl ... pulley.asp


For the alternator from DB Electrical that I already have
3 rib micro-groove pulley

# 2482251 3-Groove Pulley For Denso Alternators Used On Acura, Daihatsu, Geo, Honda, Sterling, Suzuki, Toyota 11mm Belt x 57mm OD x 15mm Bore

https://store.alternatorparts.com/part- ... ators.aspx

Thanks
rube
Reply
#107 03-14-2022, 03:43 AM,
(03-14-2022, 03:43 AM)rube Wrote: Hi,
I don’t imagine there are too many folks still looking to put an alternator conversion on a GL1200 besides me.
I tried upgrading the stock system with a series regulator and upgraded wiring, but I think the old stator is giving up.
So, I either buy a different wing or put an alternator on mine. I think I have read every thread on the topic and am now gathering parts.
So I wanted to answer my question above about pulleys.
Finding the pulleys has been frustrating, but I think I have them (on order) and wanted to post the info on the off chance that someone else was having the same problem I was in finding pulleys that work.
(This is cross posted at another site)

Pulley options I found.

V-belt
For the crank
V-belt pulley (A profile or 1/2 in wide belt) with 12 mm bore
https://www.rdgtools.co.uk/cgi-bin/sh00 ... ml#SID=585
By report this one bolts right up to the crank with a m12x1.25x60 bolt.

My alternator (Chevy mini from DB Electrical PN 400-52014) came with a 3/8 inch width v-belt pulley mounted on a 15mm alternator shaft.
To match the 1/2 in width crank pulley above….

Denso Alternator Pulley 1/2″ Belt Width X 2.717″ OD x 15mm ID

https://brillman.com/product/denso-alte ... x-15mm-id/


Micro-grove pulleys
For the crank
(I have not been able to find a power steering pump from a 1989 Honda Prelude)

Micro-groove, 3-rib pulley,
Not sure on the shaft bore on this one but recommended in one poor boy write up I read

Part # KRC 40140300

https://www.krcpower.com/ecommerce/repl ... pulley.asp


For the alternator from DB Electrical that I already have
3 rib micro-groove pulley

# 2482251 3-Groove Pulley For Denso Alternators Used On Acura, Daihatsu, Geo, Honda, Sterling, Suzuki, Toyota 11mm Belt x 57mm OD x 15mm Bore

https://store.alternatorparts.com/part- ... ators.aspx

Thanks
rube

Hello Rube,

I wanted to thank you for supplying the parts list. While I think you are right concerning the fact that not a lot of people are still converting these old bikes, I love how helpful the community still is.

It seems though, that your URL's have been shortened/not working. Could you maybe post them again? Thank you in advance.

Greetings from the Netherlands
Reply
#108 03-21-2022, 12:13 PM,
I WAS BEGINNING TO THINK I WAS THE ONLY ONE LEFT TRYING TO CONVERT ONE OF THESE OLD BIKES AND WAS ON THE VERGE OF JUST TRYING TO FIGURE IT ALL OUT FOR MYSELF SINCE THE CONVERSION KITS ARE NO LONGER AVAILABLE. MINE HAS LESS THAN 35 g ON IT SO IT'S WORTH THE TROUBLE TO DO THE CONVERSION. YOURE LINKS ABOVE DOESN'T WORK AND I WOULD GREATLY APPRECIATE IT IF YOU MIGHT REPOST THEM..... THANK YOU
Reply
#109 12-27-2022, 03:01 AM,
Wanting to do the conversion but wondering how many amps alternator I need?
Reply
#110 01-24-2023, 06:27 PM,
Has anyone used a thin 8 inch aftermarket electric fan? I found one that was 2.5 inch thick
Reply
#111 02-02-2023, 06:20 AM,
After exhaustive reading.... just wondering if anyone can share a diagram of the brackets and a list of parts. The shim for the lower radiator and better yet a source? I'm not much of a fabricator and I think I may need to get the bracket made. Also..... it will make my life way easier.

Thanks,
Reply
#112 08-16-2023, 07:52 PM,
(08-16-2023, 07:52 PM)ESossner Wrote: After exhaustive reading.... just wondering if anyone can share a diagram of the brackets and a list of parts. The shim for the lower radiator and better yet a source? I'm not much of a fabricator and I think I may need to get the bracket made. Also..... it will make my life way easier.

Thanks,

Let me know if you find (or found) a detailed parts list, PLEASE!! Thanks
Reply
#113 02-23-2024, 03:50 PM,


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