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Honda Goldwing Poor Boy Alternator parts list 2025

Written by

Tyler Watthanaphand

in

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

Comments

One response to “Honda Goldwing Poor Boy Alternator parts list 2025”

  1. Will Tucker Avatar
    Will Tucker

    Thank you for your hard work on this write up! I followed your guide to a T and got my 1985 G1200 LTD back on the road.

    Reply

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