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Poor boy vs stator

2054 Views 25 Replies 10 Participants Last post by  RambozoClown
I've got an 84 1200 interstate with 97000miles and a dead stator leg. I'm trying to decide the best option to repair/upgrade the charging system. I have read many post here and on other forums but they all seem several years old. I have a few questions and any help would be greatly appreciated.

1. Is there anyone here that has a poor boy conversion if so how do you like it for the long term?
2. Is there a source for the crank pulley? Does anyone make a kit if not I am confident I can fabricate the brackets and spacers needed for mounting and do the install.
3. Are the stator repair parts found on the internet any better than the original?
4. To anyone that has replaced the stator have you had any problems in the long term?
I have to do one or the other and just hate the idea of putting a ticking time bomb back in that can go off at any time and leave me stranded. Thanks for the help, recommendations, opinions etc in advance.
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If it were mine I would put one of these in it. Stator - Alternator - Upgrade - GL1000 - GL1100 - GL1200 and a series regulator. Probably less work in the long run than a poor boy.
There is no poor boy kit being made, you have to make most of it yourself.
If it were mine I would put one of these in it. Stator - Alternator - Upgrade - GL1000 - GL1100 - GL1200 and a series regulator. Probably less work in the long run than a poor boy.
There is no poor boy kit being made, you have to make most of it yourself.
Thanks for the reply. That's the stator repair that I been looking at. Where can I find a series regulator that will work? Is there a direct replacement? Also should this stator be ok to run an additional set of led driving lights?
I don't know where to find the series regulator, I have only seen them discussed here. Yes that stator should run several extra electrical items.
Unfortunately, the OEM stator is no longer available, so Randakks is probably the next best thing.
And I think replacing the stator is the better choice. I've never seen a poorboy job I admired.
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.
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Anyone have and idea how many amps the stator puts out?
The original 1200 stator put out 350 watts @ 3000 rpm. That's something like 30 amps.
8
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:

Hood Automotive tire Motor vehicle Automotive design Tire


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:
Automotive lighting Automotive tire Motor vehicle Tread Automotive design

Tis picture is of a GL1000 that did the iron butt cross USA in 2017 I think, nice custom, clean install:
Automotive fuel system Hood Vehicle Motor vehicle Automotive tire
Wheel Tire Sky Fuel tank Cloud

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:
Rectangle Slope Parallel Font Diagram

Here's a picture of the brackets with the lower being different. The new lower bracket uses the initial lower bracket 1" angle:
White Font Rectangle Automotive exterior Tints and shades

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):
Wheel Tire Automotive tire Bicycle part Rim
Grey Font Jewellery Auto part Circle

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
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Poorboy is a good modification if that is what you want/need.
I Archived this post for future Reference.

Thanks for the Best Write Up on both the Series Regulators, and the Poor Boy mod, in a Single Post.

Series Regulators for the GL bikes
I did the PB conversion and fabricated all my own parts, and sourced the pulley from the UK. It took me awhile to do it, and while it works, I worry about the pressure put on the crankshaft to keep the belt tight. I used a Chevy one wire mini alternator and it puts out enough to keep the battery fully charged. It's small, so it fits inside the fairing and you can't see it at all from the side. Check my posts (about 3 years ago is when I converted) and I watched a youtube video by Chris Earlywine to get some specifics and the name of the manufacturer in the UK.
I posted somewhere that I had ordered a pulley from the UK , 'cause I coudn't find one here with a 12mm bore.
He suggested another source for that front crank pulley. NOW, I can't find that post. i can't even remember if it was here or another GW forum. if anyone has seen that post I would appreciate it if you give me a shout. Thanks.
be blessed,DT
I posted somewhere that I had ordered a pulley from the UK , 'cause I coudn't find one here with a 12mm bore.
He suggested another source for that front crank pulley. NOW, I can't find that post. i can't even remember if it was here or another GW forum. if anyone has seen that post I would appreciate it if you give me a shout. Thanks.
be blessed,DT
I was able to find several on eBay that have a 12mm bore.
I posted somewhere that I had ordered a pulley from the UK , 'cause I coudn't find one here with a 12mm bore.
He suggested another source for that front crank pulley. NOW, I can't find that post. i can't even remember if it was here or another GW forum. if anyone has seen that post I would appreciate it if you give me a shout. Thanks.
be blessed,DT
Is this it? Poorboy alternator kit for GL1200
Well I have ordered an alternator and pully
Well I have ordered an alternator and pully
Could you make a list of used materials and keep us updated on the progress of the work with some photos?
I haven't started the install yet as I am still waiting on the pulley. I plan to make my own brackets. I will post pics as I do the install. The pulley and alternator are from eBay. I could not figure out how to post a link so here are the item descriptions you should be able to copy and paste them to find them on eBay. You have to choose the bore size you want on the pulley when you order it.

New Mini Alternator fits Denso Hot Rod Race Car Black 70 Amp One Wire Street Rod

V Groove Pulley Bore 8-25mm OD 100mm for 6mm O Shape PU Belt Round Belt DIY
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Has anyone used an aftermarket electric fan? I found an 8 inch that is only 2.5 inch thick was wondering if this would clear the fan and pully better
That's fairly thick and you will probably have to move the bottom of the rad out more than an inch. An 1800 rad fan is more slim and works fine, that is what I use.
I ask in the other forum also but wondering how hard the 1800 fan is to mount on the 1200.

I just went and measured my 1200 fan and it's only 2.5 in thick so the only gain would be that the aftermarket fan is thinner on the edges.
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