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Well, I got about 125 miles on this bike after getting the fuel system cleaned and the carbs rebuilt/adjusted.Earlier this evening, the wife and I have our helmets on and getting ready to go again when I discovered the bike would not start. It rolled over a couple of times and the battery went dead.Jumped it to get it back into the garage and grabbed my DVOM to see what was up. The charging system was only putting out 11.88v, ouch. I pull the yellow wires loose and checked across the connections (a-b, b-c, c-a) and got AC readings of 24.8v, 27.5v., and 33.6v at 3-4000 rpms. Shut it down and drew a long sigh....:(. After readinga couple of posts here, I guess the stator has gone down for the count.I had another 84 Aspy that I paid a shop to replace the stator in and it cost $1200. Whether I want to or not, I ain't makin' that guy's boat payment again, so I am doing this job myself.

Does anyone have advice as to the best place to buy a stator? I could go with the OEM, but since the original did not hold up, I'm a little leary of them. I vaguely remember awebsite that offered heavy duty rewound stators.I thought about the auto alternator solution, but I do not have the time currently to do the conversion, so that is just not an option at this time. I already have the engine 75% ready to drop out. I plan on replacing the thermostat and probably the timing belts while I am at it. Thanks in advance!
 

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I would lean heavily towards the GM alternator conversion. Mine has an updated stator and I am not too impressed with its output when I turn on my fog lights. It makes me think it will be overworked as the battery draws down after about 1/2 hour at highway speed. There is a lot to be said for a 55-60 amp alternator, and from what I read in the instructions it looks fairly easy to do. The nice part is about the only stock part you alter is the timing cover, and once installed you have to look hard to see it.

thats my opinion for what its worth :baffled::alco:
 

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I would talk to a good mechanic. I have the same trouble right now with the 84 Aspy. My mechanic has been specializing in Wings for the past 25 years. He says if I prepare the bike for the job, he will do it for 800Cdn. All I have to do is remove all chrome bits, covers and engine guards. Thus I save HIM time and work and I save some bucks. He will install a reworked stator with heavy guage wire.The local dealer here wants 1200 for the same job and will replace the old stator with an OEM part which we all know is junk anyhow. This is the 3rd stator for this bike. The guy I bought this bike from had the stator replaced in 1985 by a Honda dealer and they even put that stupid plastic connector back in without the hardwire method. thats why I now need a new stator AGIAN

Perhaps you can arrange such a deal with a mechanic whereby you do some of the work



Speedbird
 

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Wendell, I know the AC voltages are a bit low, but I would expect to find at least one of the readings to have near zero voltage.

Did you check the connector at the regulator? Mine had a bad hot connection there. Also, check the wires on top of the starter relay, just to the right of the battery. The charging current goes thru this connector, then to the ignition switch and battery.

From what I read, the auto alternator conversion is fairly easy. Some people even make their own mounts.
 

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Here is a couple of pics I have that came with the instructions a member provided.









 

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I know some people are sceptical about the alt conversions. but once i seen mine installed i dont see any reason it wouldnt last forever. 200 bucks and about a half a day of work and your back on the road, Hammer
 

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I installed Don's conversion kit in my bike this spring. After 7000 miles I have absolutely no complaints. The kit was very easy to install and unless you know where to look you can't tell it's there. I run 55w driving lights all the time and the alternator has no trouble keeping up.
 

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I have a photo of Don's conversion kit that he had sent me. I have been looking through alot of websites for the stator and not seeing anything worth while.Hammer, was the job of opening the hole in the timing cover a problem? I have not dropped the engine yet andthought about the conversion overnite, even dreamt about it.What about the side cover, will it need any mods to get a nice fit? I remember someone mentioned a heat gun, which would probably work good.What type and size of belt did you use?It looks like Don's kit includes a longer crank bolt. It's been awhile since I wired an alt up from scratch(in a demo derby car), so I'll have to figure the wiring of the unit. I'm pretty sure that the stator can be left unplugged without any problems. Thanks!
 

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The small raised circle on the ends of where the timing covers meet it about the exact size of the opening needed. I just used a grinder and ground the 1/2 circle in each cover.

If you look and the picture the edge of the bottom fairing just above the crash bar has a slight buldge to clear the alt. I slowly heated with a propane torch and made the buldge with the body of a tape measure.

The alt is easy to wire. You run a wire to the battrey from the nut on back of alt. Then one wire from a switched power source to a spade terminal on the back of the alt ( I_I ) The stator plug is left unplugged.

Don gave me the belt number to get but I have it a work so I don't have the number right now.

Don Pigott is very good at answering any question you might have on the conversion. His address is [email protected]
 

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I have 1700 miles on my bike since doing the Alt conversion and the only problem I had was the belt chirped,so I had to retighten it.It works wonderfully and have no regrets to doing it.

I ride with a bunch of Harley guys,and they point out my alternator to new friends immediately,,they think its the greatest thing..of course,not having to stop at every Harley shop with them for mechanical advice is the best thing to me.

You wont even know the alt is there.It doesnt effect the bike at all,and its well hidden.The 1000 bucks you save and time down in the shop is worth doing the job itself.

Lots of guys here to help too.Hammer was tremendous help to me :D Make sure you get a bunch of washers to use as spacers,and replace anything you think n:Deeds to be while in there.I did my belts,Radiator hose and clamps,and rewired the fan as it looked crappy.
 

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Good tips,Mr 1200.Did you still have to cut the Alt to fit? I had to take off the one section where a long bolt had passed through when the ALt was used on a car.

I also used my grinder to make the hole in the Timing covers.I just followedoutline of the pulley Poorboy Don gives you.I couldnt figure out anything to use to "seal" the hole.

I thought the worse part was cutting the black piece that extends off the fairing below the radio control knobs/cig lighter.
 

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Good tips,Mr 1200.Did you still have to cut the Alt to fit? I had to take off the one section where a long bolt had passed through when the ALt was used on a car.

I also used my grinder to make the hole in the Timing covers.I just followedoutline of the pulley Poorboy Don gives you.I couldnt figure out anything to use to "seal" the hole.

I thought the worse part was cutting the black piece that extends off the fairing below the radio control knobs/cig lighter.



BTW,I used a 29 inch belt,but could havr used a 29.5 als0.
 

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sorry bout that, had a busy weekend, really the only visable modification is the side panel that you have to heat up to fit the bottom of the alt. the rest is pretty much common sense nipping and tucking . kinda have to feel your way through it im sure not all bikes a exactly the same, but it sounds like these guys have you pointed in the right direction. a good hand grinder to flatten out the horn bracket . a saw zaw and a bench grinder seved me well through my conversion
 

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