Denso 40 Amp Alternator

[Cookie]

Interesting job sport. As for water what do folks think happens when a car drives though a rainstorm? A lot of water gets pushed in there at speed.
I once had a Chevy V8 that I had adapted an alternator to that would throw belts when it revved to 7,000 rpm. That alternator must have really spun at that speed but it never hurt it. My solution was to disconnect the belt when drag racing.
I would think that would work very well on a wing. Dan Cason put one on his Chang and I believe it works fine.

[tirejoe]

WF on my bike 4" crank pulley 2" alternator pulley, has turned7,500 rpms a lot. No problems in 11,000 miles. It charges 14 volts at 950rpm.

[ofc.w.poss]

Very interesting thread I have been thinking of boosting the charging system on mine during the rebuild. I would really like to see pics.

[Whiskerfish]

WF on my bike 4" crank pulley 2" alternator pulley, has turned7,500 rpms a lot. No problems in 11,000 miles. It charges 14 volts at 950rpm.

Cool. I went to 6 places yesterday looking for the correct pully. I will be hitting Northern Hardware and the local Toro/ Lawnmower shops today.


For those that are thinking about this on a bike with a stock Radiator I am not sure how it is accomplished. The way I am bolting this up, the belt will definetly interfere with the fan shroud. My dressed bike uses a fan on the front of the radiator and the stock fan shroud will be removed for clearance. Pushing out the bottom of the Rad is the only solution I can see??

[CYBORG]

on a stock set up, push the rad. out about an inch, anf mount the alt. on the left side of the bike

[CYBORG]

i think the rad. has to come out the inch or so to clear the pulley

[paultjack]

While searching for the much-needed Clutch Nut Tool plans that I think Whiskerfish ad posted at one time I came across this site which has two alternator conversions. Not sure if there'll be any helpful info there but I thought it might give insight as to how someone else also did this conversion.

http://www.htctech.net/~squirts/stator.htm
http://donaldantiquerototillers.com/Alternator.html

[Whiskerfish]

I have looked at Donalds (Rototiller not Poorboy) several times. I met him at the first Randakk rally. Horrible crash he had with that bus. I am not sure if he has gotten back into Wings or not. What is really interesting is that he has a breakdown on his page of exactly the issue that Alan Hawke just went through with his rear hub missing the spacer here http://www.donaldantiquerototillers.com/Motorcycle.html Apparently this is not an uncommon issue with older Wings and the problems they develope as they change hands throughout their lives.


I have several reference pages but they are all basically the same. The only real difference is their work is higher quality and they are using a single wire alternator. I think Rotortiller Donald was running a 105 amp alt which is just a bit excessive in my mind. The 40 amp denso is like a 80% increase over stock.

The job is not terribly difficult but having the Rad fan on the front and using a stock Fender is a bit problematic for me. I already have an interference issue with the fender when hard on the front brake and I May have to push the bottom of the rad out a hair to get clearance for the pulley. That will certainly exacerbate the fender issue. I may have to swap the fender for one that fits tighter to the wheel or end higher and not provide the protection I would like for the oil filter and radiator.

I got 2 different sizes of Pulley yesterday with all the pieces I need to get the arbor bore down to the 10 mm bolt size. I hade one pulley already for a 1 to 1 ratio so now I will have 3 options for ratio. All 3 are narrow profile so it just depends on clearance and if I can accomplish a decent charging rate at idle. It is going to take some experimentation. Still nothing back from Denso.

The weather is good today and the Wife is here to help so my 55 gallon fish tank is going outside for overhaul and then be moved into the living room. So no wrenching today

[alan hawke]

[quote="Whiskerfish"]I have looked at Donalds (Rototiller not Poorboy) several times. I met him at the first Randakk rally. Horrible crash he had with that bus. I am not sure if he has gotten back into Wings or not. What is really interesting is that he has a breakdown on his page of exactly the issue that Alan Hawke just went through with his rear hub missing the spacer here http://www.donaldantiquerototillers.com/Motorcycle.html Apparently this is not an uncommon issue with older Wings and the problems they develope as they change hands throughout their lives.



Glad to see i'm not the only one.

[Grinsha]

Here are a couple pics of my alt. install.
It's a 90's Geo Metro 55amp unit.
The crank pulley is off of another geo alt. 1-1 drive.
The belt is from a '91 Geo Metro.

http://www.flickr.com/photos/grinsha

RSN

[Whiskerfish]

Very nice. I like how you did your brackets. I am going more for the bolt on application but If I don't like the way it mounts up I may look more at that.

[lsgyger]

Here are a couple pics of my alt. install.
It's a 90's Geo Metro 55amp unit.
The crank pulley is off of another geo alt. 1-1 drive.
The belt is from a '91 Geo Metro.

http://www.flickr.com/photos/grinsha

RSN

Your top bracket - what was that from or a part of? Kind of looks like a fairing mount.

[LikeMike64]

Whiskerfish, I found that on a '76 you can swing the bottom of the radiator forward 3/4" with spacers without the stock fan hitting the thermostat housing or having to do any mods for the lower radiator hose. More than that, and you have to mods.

If you mount the alternator on the right side of the bike, would it clear the stock fan? That would cure your fan/front fender issues.

[Grinsha]

The upper mount is from the geo the alt. came from. I cut most of it off and welded it to the frame. I just put the false tank back on it yesterday. I had to cut some of it to clear the mount.
Haven't remounted the rad yet. Will figure that out when i get there.
I will post a few more pics of the alt. on my flickr page for clarity.
RSN

[Whiskerfish]

Whiskerfish, I found that on a '76 you can swing the bottom of the radiator forward 3/4" with spacers without the stock fan hitting the thermostat housing or having to do any mods for the lower radiator hose. More than that, and you have to mods.

If you mount the alternator on the right side of the bike, would it clear the stock fan? That would cure your fan/front fender issues.

Actually my issue is with the pulley clearance. I have my fan mounted to the front of the Rad. It already interfeers with the fender on hard braking. Moving the Rad out slightly at the bottom is an issue for me because of that. With a 1 to 1 ratio pully I think it will clear the rad but larger I think I will have an interferance issue. I still have to look at it some more.