[Bschofield]

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I just got back from the junk yard. picked up some pulleys and a 94 geo metro alternator, stopped @ autozone, checked it out. all good. now to tear down the bike and start the modifications! will post pictures of the progress. i expect to have it done by the end of the weekend. so far less than $60 spent.

Barry

 

[Bschofield]

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Well, spent many hours working on this project yesterday, I think there was more @ ace, autozone, homedepot etc. the big problem i faced was the pulley, and being a sunday i had few options. so in the end i found a steel idler pulley, @ 3 inches. popped the bearing and fabricated a centerpiece. I also fabbed a center post with a keyway to fit in center keyway, and also a lip for the belt shield. I modified a piece of the fairing bracket to make room. also cleaned up the alternator and cut off the rear tab. I believe i will be able to use the adjuster that was on the alternator with a bracket. today i will finish the pulley, cut the hole in the covers, mount the alternator, and be done! (I HOPE) raying:
following are pics:

this is the idler i chose:

here is the Center that I fabd from a 12mm nut and 2 washers:

here is the centerpiece welded in:

My bike just waiting anxiously!

here is the alternator and some pulleys i grabbed from the junk yard. they were too big.

Here is the alternator in a bag for protection from metal bits: after i cut off the rear mounting flange.

I will post more pics as i go.

Barry

 

[Bschofield]

imported post

UPDATE!
today I took the wing out for it's maiden voyage on my custom alternator install.
after 80 miles I was very happy. I could actually listen to the radio again! and I got home with a full battery for the very first time!. it actually ran better as well. minor issues to address before putting the plastic back on.
1. my custom crank pulley is a bit off, and so i get low rpm vibration. (pretty good considering i didn't machine it!)
2. need to cut out the holes in the timing belt covers.

I am also going to put a relay on the coils to get a more direct power to the coils.
and rearrange the wiring a bit for future addons.

Pictures of all of the steps tomorrow. :claps:

Barry

 

[Bschofield]

imported post

Another 80 miles yesterday, machined down the center pulley, almost all vibration gone. going to do a bit more on the pulley, also going to mount an end connection to my fabricated frame to have it connect as a stabilizer against the crash bar, as i don't feel it is secure enough on lateral movement. my thoughts are that they designed with the rear bolt mount for a reason, and for me to grind it off and not compensate could lead to a failure of some sort.
Sorry about the images, they worked for a while, I must have posted them wrong. I will try to educate myself on posting images today and repost, as well as post new ones.

Overall I would definitely do this again, it has cost me more time than money, the only things i have noted are: my idle is down just a little, and i can get it to squeel just a bit on cold starts with a quick wot, no real negatives. AND i didn't have to pull the engine!

Barry

 

[Bschofield]

imported post

Saws, that has been kicking around in the back of my mind, my intention was to pull the stator when i need to do some type of maintenance inside... but now i may do sooner. thanks for the heads-up
Barry