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Tag: gl1200

  • Honda Goldwing Poor Boy Alternator parts list 2025

    I just completed a poor boy alternator on my Honda Goldwing GL1200 Aspencade. I tried my best to document any tips and all the parts I purchased to complete the project below.

    Youtube Video: https://tinyurl.com/poorboy-alt

    This document uses affiliate links, and I earn a small commission when you purchase parts using the links on this page.

    Pulley & Belt

    • KRC Power Steering Pulley B005JVGX4M  KRC 40140300
    • Bushing 5448T427           12mm ID 17mm OD 9.5mm shaft
      • (goes inside the pulley to fit the M12 bolt), Requires minor sanding of OD to fit inside the pulley
      • $10.25
      • McMaster-Carr
    • Lock washer 91477A200       M12 screw, 29mm OD
      • Provides clamping force on KRC Pulley from M12 bolt
      • $6.43 ($0.64 used)
      • McMaster-Carr
    • M12 Bolt 91180A905       25×60 Class 8.8 Bolt
      • Longer bolt to accomidate pulley and spacers, Class 8.8 meets the torque requirement of the bolt
      • $13.87 ($1.39 used)
      • McMaster-Carr
    • Brass Flange Bushing 7634N19             1/2″ ID, 3/4″ OD, 3/4″ len
      • Required sanding non flanged side to get the pulley closer to the timing cover
      • $4.94
      • McMaster-Carr
    • Gates or Equiv belt 295K3 or K030295        Belt 3 Rib, Micro-V, 29.5″
      • Your belt may be different, use a string to measure proper belt length
      • $14.29
      • Purchase Guide

    Alternator

    • Nippon Denso Reman Alternator 321-1250            for 91 Geo Metro, 3 rib pulley
      • 55 Amp, 3 wire alternator with T shape round plug, price incl core, rear mounting tab needs cut off
      • $157.79
      • RockAuto
    • 2x Alternator mounting bolts                        25 bolt
      • Top mount is threaded
    • Alternator mounting nut M8 1.25 nut
      • Lower mounting lock nut
    • 8x Upper alt bracket spacer washers    ZHUYU009        M5 washers
      • Spacer washers for top bracket, used to space bracket from fairing mount, 8 needed, 4 on each side of the bracket
      • $10.99 ($0.05 used)
      • Amazon

    Radiator

    • 2x Round coupling nut    90202A441       10mm, 25mm len, M6x1 thread
    • Threaded rod 90024A227       M6x1 threaded rod
      • Extends bottom radiator mount threads, Cut to size
      • $4.61
      • McMaster-Carr
    • Longer coolant hose NBH7733           1″ heater hose
      • Probably not required, compatible models: gates 21008, napa NBH7733, AutoZone Duralast B70834, AdvAuto CarQuest – 21029
      • $14.00
      • AutoZone
    • Longer radiator fan bolts 95911A311       8x16mm
      • 3 longer bolts, philips head, allow the fan to be pushed closer to the radiator so the blades do not touch the alternator belt
      • $6.00 ($1.80 used)
      • McMaster-Carr
    • Spacer nuts for radiator 94150A340       8
      • These nuts are used as a spacer to push the fan closer to the radiator by a set amount
      • $6.07 ($0.36 used)
      • McMaster-Carr

    Steel

    • Flat Steel stock 2279541              1″ x 1/8″ x 3′ flat steel, low carbon
      • Bracket Building, Home-Depot will have it, but more expensive. Try Menards, McMaster, Lowes instead
      • $4.79 ($3.19 used)
      • Menards
    • Steel angle stock 2279703              1″ x 1/8″ x 3′ steel angle
      • Bracket Building, Home-Depot will have it, but more expensive. Try Menards, McMaster, Lowes instead
      • $7.71 ($2.14 used)
      • Menards

    Welding

    • Arc Welder B08CBBHFX5 YESWELDER FLUX-135PRO
      • Any arc welder will work, starts at $60 on Amazon
      • $116.00
      • Amazon
    • Welding Rod FleetWeld 37-RSP        1/8″ E6013 welding rod
      • 3/32 may be a better option for this, used 2 rods for this project
      • $21.98 ($0.88 used)
      • Home Depot
    • Auto tinting welding helmet B07QJ1Y527
    • Chipping Hammer B002ACOXNG                 Hobart 770066 Chipping Hammer
    • Wire Brush B07CD9QR25 Lincoln K3185-1 Wire Brush
    • Welding Gloves B01N1VJDIQ    RAPICCA Welding Gloves

    Electrical

    • Alternator plug B0DFMBBZ48 Alternator 3 wire nippon denso style plug
    • Inline Fuse/Circuit Breaker B0BZHL4LVB  40A
      • Install as close as possible to battery
      • $14.85
      • Amazon
    • Copper Wire B08K2MMYCT                  8ga, 25′, OFC Copper
      • From alternator to battery, only need 5′ max
      • $19.99 ($4 used)
      • Amazon
    • Copper Wire B07588953X    14ga, X’, OFC Copper
      • From alternator plug to accessory wire (15A Fused), only need 5′ max
      • $7.99 ($4 used)
      • Amazon
    • Wire Terminal Ring B08R6WHRPQ                8ga
      • SOLDER the terminal rings, for thick wire between alternator and battery, need 2 pcs for this
      • $6.67 ($1.33 used)
      • Amazon
    • Wire Terminal Ring B0CYM3J44Q 14ga
      • Can Crimp. Connect this between Alternator plug and positive post on fuse box above airbox, need 1 pc for this
      • $7.58 ($0.08 used)
      • Amazon
    • Butt splice B0D5GNJ1MR                  14ga
      • Need 14ga for splicing alternator plug to 14ga wire to accessory fuse, need 1pc for this
      • $9.99 ($0.05 used)
      • Amazon

    Misc (things you may already have)

    • Paint B000PIEWLA                     Enamel spray paint
    • Drill Press B08ZVT5JKC                      Drill can be used, used for bracket making
    • Drill Bits B079VJMH6T                     used for bracket making
    • Angle Grinder B07P5D6M4V incl Cut off disc, Grinding Disc
    • Safety Glasses B01A12J3GI
    • Soldering Iron Kit B08R3515SF
    • Wire Crimp Tool B0BGXDD5Z8