Alternator Took a Dump

[Bighead]

I was in Bristol TN on Friday heading into Va when I look down and the speedo and Tach wasn't working within just a couple of miles she started sputtering well I pull to the side of the road and called a Guy in Johnson city and he came out and brought a fresh battery to get me to his house but while waiting the Battery rebuilt some charge so when he got there I pulled the headlight fuse and Hauled ass to his house ,it was about 12 miles to his house. one mile from his house she died. swapped the battery and went on to his place where I removed the dead alt and then had a beer so Saturday morning I called the local Honda stealer and was in luck as they had a alt for a wing. bought it reclocked the face and put her in. I have heard all the horror stories about putting one in (or taking one out) but it was not bad at all.the hardest part was the rubber damper that the fins fit it. the one on the top kept falling down but a little smear of grease and she hung up there like a hair in a biscuit  .
one tip for those that haven't done it remove the noise suppresser ( I think thats what it is) and put it back on after alt is back in place. It almost fell in once I removed that
Just wanted to give a shout out to Charlie for the assist
Oh BTW the bike only had 42,800 on the clock ???

[Tfrank59]

42K--kind of an untimely death, no?  Thanks for the update.  I guess it's common knowledge that a wing alt will fit?  And what do you mean by reclocked it? (prob also common knowledge)--changed the angle on something methinks.

[Bighead]

To make a wing alt fit you have to move the Face 1/4 turn so the wires will reach. If you don't do this the wire to the battery is too short.

[old2soon]

It's the cheap azz chinese wire some of em were wound with.  RIDE SAFE.

[Tfrank59]

To make a wing alt fit you have to move the Face 1/4 turn so the wires will reach. If you don't do this the wire to the battery is too short.

Okay that's good to know. Excuse my laziness but is there some discussion of this in the shop talk pages? .  I'm also curious if you don't mind sharing how much did the Stealer charge you for that GW alternator?

[The emperor has no clothes]

To make a wing alt fit you have to move the Face 1/4 turn so the wires will reach. If you don't do this the wire to the battery is too short.

Okay that's good to know. Excuse my laziness but is there some discussion of this in the shop talk pages? .  I'm also curious if you don't mind sharing how much did the Stealer charge you for that GW alternator?

This might help a little. There are also old threads about it.

http://www.jkozloski.com/generic_parts.htm

[nomoreharleys]

So if the battery goes the whole bike shuts down?

[Houdini]

So if the battery goes the whole bike shuts down?

If the alternator goes the bike shuts down once the battery is used up.

[Bagger John - #3785]

The service manual spec's an alternator brush replacement at 45k.

This interval may be shortened (brushes consumed faster) with a heavy electrical load - such as with a high-powered headlight and incandescent driving lights.

I replace them at ~36-38k regardless.

[98valk]

The service manual spec's an alternator brush replacement at 45k.

the manual does not state that. There is not a replacement interval.
 The installation holes are not the wear indicator which is lower on the brushes.
Just had mine apart at 52k miles. brushes were before the holes. However the rear bearing was starting to go. I replaced with one from NAPA which is a better design and used on other alternators.

[John Schmidt]

Hey Bighead, that "Charlie" you mentioned....was that my old friend Charlie Mac? 

[Bagger John - #3785]

the manual does not state that. There is not a replacement interval.

Might want to look around a bit.

One such manual I have here does out call that interval for GL1500 alternators.

ETA:

'97-01 GL1500C Service Manual does not, so you're technically correct.

[98valk]

the manual does not state that. There is not a replacement interval.

Might want to look around a bit.

One such manual I have here does out call that interval for GL1500 alternators.

ETA:

'97-01 GL1500C Service Manual does not, so you're technically correct.

which manual?
 I have factory Valkyrie and Goldwing manuals neither state a mileage replacement. If its a clymer manual they are incorrect.
 Honda automobile alternator brushes always last min 100k miles.
And as I stated mine at 52k miles were not half worn, but the bearing was starting to go.

[Bagger John - #3785]

which manual?
 I have factory Valkyrie and Goldwing manuals neither state a mileage replacement. If its a clymer manual they are incorrect.
 Honda automobile alternator brushes always last min 100k miles.
And as I stated mine at 52k miles were not half worn, but the bearing was starting to go.

Clymer - I think.

That figure was also thrown out on the old Tech Board a number of times as I recall.

I did my first alternator - my '00 Tourer's - at 36k. Electrical loading - in addition to the stock equipment - was a set of 21/3w turn/running lights in the rear, three 2w lamps for additional gauges, a pair of 35w HD-style incandescent driving lights, a Hondaline CB and a FRSet-4 system integrator.

The brushes in the alternator were worn to 1/8" of the limit holes at that mileage. 

[98valk]

which manual?
 I have factory Valkyrie and Goldwing manuals neither state a mileage replacement. If its a clymer manual they are incorrect.
 Honda automobile alternator brushes always last min 100k miles.
And as I stated mine at 52k miles were not half worn, but the bearing was starting to go.

Clymer - I think.

That figure was also thrown out on the old Tech Board a number of times as I recall.

I did my first alternator - my '00 Tourer's - at 36k. Electrical loading - in addition to the stock equipment - was a set of 21/3w turn/running lights in the rear, three 2w lamps for additional gauges, a pair of 35w HD-style incandescent driving lights, a Hondaline CB and a FRSet-4 system integrator.

The brushes in the alternator were worn to 1/8" of the limit holes at that mileage. 

yes, it was recommended to pull and clean out the rear bearing area at around 50k miles. Many did not read the manual and assumed the holes where the replacement indicator, they are not. The holes are for installation, they are not the wear limit. There is a wear line past the holes. manual calls for replacement when at or near the lines.

[Chrisj CMA]

which manual?
 I have factory Valkyrie and Goldwing manuals neither state a mileage replacement. If its a clymer manual they are incorrect.
 Honda automobile alternator brushes always last min 100k miles.
And as I stated mine at 52k miles were not half worn, but the bearing was starting to go.

Clymer - I think.

That figure was also thrown out on the old Tech Board a number of times as I recall.

I did my first alternator - my '00 Tourer's - at 36k. Electrical loading - in addition to the stock equipment - was a set of 21/3w turn/running lights in the rear, three 2w lamps for additional gauges, a pair of 35w HD-style incandescent driving lights, a Hondaline CB and a FRSet-4 system integrator.

The brushes in the alternator were worn to 1/8" of the limit holes at that mileage. 

yes, it was recommended to pull and clean out the rear bearing area at around 50k miles. Many did not read the manual and assumed the holes where the replacement indicator, they are not. The holes are for installation, they are not the wear limit. There is a wear line past the holes. manual calls for replacement when at or near the lines.

Not to be a PITA here.  I open up my alternator every 50-60K miles.  If the brushed are worn any where close to the
holes they get changed. Yes I understand they are not supposed to be wear indicators but it works for me.

[98valk]

which manual?
 I have factory Valkyrie and Goldwing manuals neither state a mileage replacement. If its a clymer manual they are incorrect.
 Honda automobile alternator brushes always last min 100k miles.
And as I stated mine at 52k miles were not half worn, but the bearing was starting to go.

Clymer - I think.

That figure was also thrown out on the old Tech Board a number of times as I recall.

I did my first alternator - my '00 Tourer's - at 36k. Electrical loading - in addition to the stock equipment - was a set of 21/3w turn/running lights in the rear, three 2w lamps for additional gauges, a pair of 35w HD-style incandescent driving lights, a Hondaline CB and a FRSet-4 system integrator.

The brushes in the alternator were worn to 1/8" of the limit holes at that mileage. 

yes, it was recommended to pull and clean out the rear bearing area at around 50k miles. Many did not read the manual and assumed the holes where the replacement indicator, they are not. The holes are for installation, they are not the wear limit. There is a wear line past the holes. manual calls for replacement when at or near the lines.

Not to be a PITA here.  I open up my alternator every 50-60K miles.  If the brushed are worn any where close to the
holes they get changed. Yes I understand they are not supposed to be wear indicators but it works for me.

send me the ones u take out, their good for another 50k min. I'll never have to buy new ones again. thanks. Brushes in any alternator normally last min of 100k miles.

[Chrisj CMA]

Lol.  Brushes are like two bucks each.  Would cost more to send used ones to you.

[98valk]

Lol.  Brushes are like two bucks each.  Would cost more to send used ones to you.

Road Trip 

[Bighead]

Hey Bighead, that "Charlie" you mentioned....was that my old friend Charlie Mac? 

Yes John it was Charlie Mac a good man first met him about 12 yrs ago when I was standing outside my motel room in Marion NC Sipping a cool one when this Red/Black IS pulled up and we talked a bit then never seen him again until about 4 yrs ago on one of Smokin Joes rides. Got his # then and Damn if it didn't come in handy
And as far as the stealer Price on the Alt lets just say it was $100 more than you can order one for but what Ya gonna do? I am just glad the wife packed bags on that bike instead of the other as we are leaving this Thursday for 16 days and I would have been in BFE when it went out
And BTW my 97 has 100 k on it and still has original alt in it so maybe time to inspect the brushes

[Willow]

...
And BTW my 97 has 100 k on it and still has original alt in it so maybe time to inspect the brushes

I hate to butt in on a fruitful discussion.  My Standard has 185K on the original.  One of my Interstates went out at about 40K.  Electrical loads are certainly different but it appears also that alternators themselves and riding environments vary.

[vanagon40]

Seems to be crapshoot on how long the original will last. The one on my 2001 Standard died after 7 years at 14,300 miles.

[Kunkies]

Other than your Valk' dying, do you recall any pre-warning sounds like a intermittent clicking coming from the top of your engine indicating your alternator may be going?

[Blackduck]

Read somewhere the first year or so got Japanese made alternators then production moved to China and the fun began.
Be nice to know what actually failed in the alternator.
Had a wire crack in the rotor on my 01, right where it was wound around a post. Very hard to see and only picked it up after checking with a multimeter for continuity and isolating the area.

[Bighead]

Other than your Valk' dying, do you recall any pre-warning sounds like a intermittent clicking coming from the top of your engine indicating your alternator may be going?

ZERO WARNING

[Probie (Scooter57)]

Do the GW alternators put out more juice than the stock Valk one? I put on a voltmeter on my bike and when the driving lights are on I'm getting 11.6 volts when they're off I'm getting 13.7.
I've never had any issues with the battery going dead BEFORE I put the voltmeter but for some reason it bothers me now.

[Tfrank59]

I guess this is your point but I think that your battery will discharge if it's not getting something like 13.5 volts from the alternator.

[Skinhead]

Had a wire crack in the rotor on my 01, right where it was wound around a post

^^^^^^^^^^^^^^This is the most common failure mode^^^^^^^^^^^^^