Poor boy vs stator

Cosmetically the poor boy route is terrible. There is no way yo make it look good in my opinion. When the stator went in my 1100 I replaced it with an after market high output stator from Ricky Stator on eBay. I know pulling the motor is a big job, alternatively they say you can do it by pulling the swing arm. I pulled the motor.

If you do replace the stator all you can get these days is aftermarket. Most if not all of which are higher output than the OEM. Therefore you will need to replace the voltage regulator with aftermarket as well. I learned this the hard way. Went through three OEM regulators before figuring out that they were just not up to the task of regulating the higher output stator.

Long term...no issues, I could run all the lights, stereo, accessories I wanted without a problem. I was worried about there being issues so I installed an ammeter between the main fuse and starter relay, as well a voltmeter between ignition switch and fuse box. This was so if an issue were to arise I would see it right away and maybe not get stranded somewhere.

Ammeter (measures amp draw) needs to be connected in series on the hot side of the battery. Voltmeter must be on a switched circuit (turned off with the key) otherwise it will drain the battery.

I recommend installing these two gauges regardless of which repair you choose.

Poorboy is a good modification if that is what you want/need. The key issue with stators failing IMHO is that of poor connectors over time. Dirt and crud are not the friend of the charging system. A good cleaning and if needed replacing of the wiring connectors will go a long way to maintaining and ensuring there are no charging system issues. Changing to a series RR is a good investment. The newer shunt regulators that have upgraded internal components such as Mosfets is another good consideration.

Series RRs that can be used are:

1. SH847
2. SH775 - (web site for info: DRZ400 SH775 Regulator Rectifier Upgrade )
3. Carmo Electronics CARR5925-SERIE R/R. It is half the price of an SH847. Here's the link: https://www.carmo.nl/index.php?main_pag ... ts_id=2949
4. Compu-fire 55120 series RR

Most series RRs may require a different location because of the size. I corresponded with a fellow who installed an SH847 on his '85 GW Limited Edition - I sold it to him. He installed it on the backside of the right saddlebag, worked well:

Some have commented on the look of the external alt mod. Installed an external alternator on my '85 Limited Edition some 5-6 years ago. Works well and is tucked in behind the lower left fairing cover. Looks good and if you would be hard pressed to know it is there. I was installing additional driving lights in this picture, but it shows a clean install:

Tis picture is of a GL1000 that did the iron butt cross USA in 2017 I think, nice custom, clean install:

I have changed the mounting system a bit over the years, wanted a better lower bracket. Used 1" angle for the brackets, modified to suit. Initial schematic for the parts:

Here's a picture of the brackets with the lower being different. The new lower bracket uses the initial lower bracket 1" angle:

The crank pulley is from an early model Prelude power steering pump. Went to the local fastener shop for the longer bolt. Used 3 - 1/8" thick washers and 2 - small bearings I found at Princess Auto (Canada's HF equivalent):

Used files and hacksaw to make and fit. Used a local welding shop as well, don't have a welder.
I have not regretted doing this project.

Just a few thoughts. Good luck. Cheers