Denso 40 Amp Alternator

Cookie · #31

When installing a later model BMW engine in Changs a number of folks have dented the rear of the fender to clear. I don't know if that is an option or if you have a plastic fender.

#32

Post modified due to my stupidity! LOL

TomE · #33

OK, I have waited a long time to ask what may be a stupid question.

How do you hide the alternator when done? Is there some sort of cover over it, like Windjammer lowers, or do you just leave it hanging out in the breeze?

I guess you Could chrome it....

Cookie · #34

If you hide it you can't use the fins to chop vegetables for the stew.

#35

TomE wrote:OK, I have waited a long time to ask what may be a stupid question.

How do you hide the alternator when done? Is there some sort of cover over it, like Windjammer lowers, or do you just leave it hanging out in the breeze?

I guess you Could chrome it....

use a small alt. tuck it in close. on my 1200 it fit nicly behind the lowers. could not even see it. on cyborg its tucked in, and the small cover over the regulator part of the unit is polished. function following form

detdrbuzzard · #36

http://forum.classicgoldwings.com/viewt ... &start=60s check out dan's alternator conversion, poorboy has one too over at www.gl1200goldwings.com

#37

Ok after I got the 75 off the table today I put the Dresser up there to work on the Alternator. I had it mocked up pretty good on the 75. As soon as I started working on the 78 I immediately realized thet the LH Horn mount was going to be an issue.

So I removed the vertical engine support and cut that off and reinstalled it.

I also got the belt covers cut and painted

I got things mounted up pretty good and did a rough measurement for a belt. It was no where near close!!!!

Turns out the clothes Line seated much further in the V Pulleys than the Belt does. So my measurement was off by over 1.5 inches. So 2 trips to the store instead of one. And I have my belt. I built this without a adjuster just to save time (Because I was trying to take shortcuts and being foolish). So as soon as I mounted the belt up I confirmed that I could not get by without an adjuster. So I had to fab one of those up. I looked at my clearances between the Alt. and the Intake runners and the Alt. and my Fairing lower edge and decided to mount the adjuster on the bottom of the Alt.

The Pulley allignment is somwhat adjustable using washers under my supports. I think this is pretty good.

Some folks are concerned about appearance. From the front it appears to be tucked in pretty good but from the back it stands out more.

Not certain yet but I think the radiator will clear once it is reinstalled. I did do some trimming of the stock fan shroud today and will show a pic of that when I reinstall the rad. Tomorrow I will get the rad back on and then start on the wiring. Should be up and running by mid day I hope.

#38

Nice pics dude.

Cookie · #39

I don't think with that fairing anybody who does not know wings will notice at all. Folks who do know them will go pretty neat!
Anybody who has other opinions should keep in mind you just quit smoking.

#40

Nice work Steve, that alternator looks like it belongs there. Take some time with the wiring and it will look like Honda designed it.

#41

Sagebrush wrote: Take some time with the wiring and it will look like Honda designed it.

Funny I actually spent some money on wiring supplies for this project

normally I just use what ever I have laying around.

#42

Ok I put in a few more hours today. Not gratifying hours though!! First I did the wiring. that came out pretty decent for my skill level. I ran 10 gage direct to the Battery hot terminal for the ALT output. I tested the case greound and it was good but I still ran a 10 Gage to a ground lug I have setup on the Shelter frame. Then I ran the control wires, one to ground and one to the Accessory terminal. When I started the bike the ALT worked when above 2,000 rpm.

While doing the intitial run I realized that my supports were no where near strong enough. There was too much flex while it was operating. So I made a brace for the bottom that will pick up one of the Intake runner bolts. And I made a brace for the top that goes forward to the frame and picks up support there. The forward one will be attached with a radiator clamp.

Now the ALT is very steady but it ws not charging below 2k. I swapped the pulley to the largest one I have. The Ratio is now 1.5 to 1 and it did lower the charging speed but not to where I am happy yet.

Charging now starts about 15-1600 rpm indicated. I am not sure I can fit a larger pulley but I will look at it some more. [/url]

#43

lookis good. one question. the brown wire out of the white plug on the alt. did you put that to ground? the yellow should go to a sw. positive. but the brown is for an idiot lite. does not need to be connented to anything, but would suggest running it thru a light bulb to ground if youi want to connect it

#44

CYBORG wrote:lookis good. one question. the brown wire out of the white plug on the alt. did you put that to ground? the yellow should go to a sw. positive. but the brown is for an idiot lite. does not need to be connented to anything, but would suggest running it thru a light bulb to ground if youi want to connect it

Thanks fopr catching that!! I guess I am gonna have to fix that straight away!!

peteybug · #45

Nice job! One question looks like you cut a notch in intake tube for bracket. Won't it leak a little?? Or is that just a jig for set up?

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Denso 40 Amp Alternator