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Thanks. I have alt. on both my 78, and my 84. I think I might have to increase the size of the pulley's on thr crank so that they charge at idle. Now it's 2500 rpm and above

CYBORG wrote: ↑Sun Aug 04, 2024 6:33 am Thanks. I have alt. on both my 78, and my 84. I think I might have to increase the size of the pulley's on thr crank so that they charge at idle. Now it's 2500 rpm and above

Most all the threads concerning this conversion seem to have good results with the 4 inch pulley. I'm quite pleased with the quality of pulley I purchased. A bit of a wait for shipping, but I really didn't find any other source for one that didn't require a bunch of spacers, collars, etc. One M12X65-1.25 bolt, three or four washers, and we're good to go.
Here's a link if you're interested...
https://www.rdgtools.co.uk/acatalog/4-- ... tion-.html

Thanks for the link

You're most welcome!

The radiator bump out process. The 1200's have an M6x25mm stud rather than a bolt for the lower radiator mount, and it's only threaded about half- way. I cut threads all the way down the studs and installed M6 threaded couplers that are about 20mm long. A test fit proved sufficient clearance. I then split the length of the coupler and trimmed the stud to 10mm. An M6x20 bolt installed from the front of the radiator just bottoms out against the stud when tightened. The final radiator to pulley clearance is about 1/4th inch.

The radiator fan and assorted electrical goodies should arrive today and/ or tomorrow. I should be working on the alternator brackets, but it's just too flippin' hot! The weekly forecast is calling for a bit of a cool down, but between appointments and to-do chores time slots are filling up fast!

Happy almost birthday to me! Everything except the auxiliary fuse block arrived as I was making the previous post... except for some sundry fasteners, I should have everything I need to complete this stage of the Aspy project!

My totally half-a$$ed clearance/ travel check. I know it's not very clear, but it looks like with the current setup I would have about two inches of travel before fender meets fan... probably not acceptable. I'm not sure if I want to try compressing the forks using ratchet straps, or if there might be any other options.

Comparing the coverage... The new fan is a 10 inch, and the overall width is 1/8th inch wider than the OEM radiator 'grille.' Blade to radiator distance is nearly identical between the two.
Options seem be: move the fan up on the radiator, modify the shroud and/ or the radiator side support, a combination of the two, or try a smaller diameter fan.
Moving the fan up seems the simplest, so that will be my next mockup...

I would be tempted to ratchet the forks down to see how close it comes. I do think it will be too close for comfort just by the pictures.

The front fork springs are probably original, and as such, soft/weak. Recommend an upgrade to a straight rate spring such as those at Sonic, and get the 1.2 kg/mm, will improve front end handling and minimize front end dive.

I use an 1800 rad fan. Still a tight fit but no need to modify. You only need a 1/8" space between rad fan and pulley to replace/change alt belt if needs be.

You can get a water pump spacer kit, Moroso Water Pump Spacer Kits 63611, helps with moving the rad:

Ernest, I just finished servicing the forks and replaced the original springs with a set from RaceTech, lol. I'll see what specs I can find on fan options after I do another mockup or two.

According to https://www.motorcyclespecs.co.za/model ... 00_86.html the fork travel for the '86 Aspy is 5.5 inches. The green tape in the photo is 4 inches from full extension, and I used ratchet straps to compress the forks to nearly the point of contact between fan and fender. The gap shown is about 3/4th of an inch, so the travel before contact would be 3 1/4th inches. I will say that the straps were really straining to get it to that point... Will the front really dive 5.5 inches?
I didn't take a pic of the fan coverage, but it's now installed as high as it can go. I would estimate 5/8ths of the fan actually covers the radiator core area.

Under hard braking, yes the forks will travel farther than you can pull them down with a strap. I've tied some down pretty tight and didn't get near the witness marks from where the dust seal had reached before leaving an oil film around the fork.

On a hard stop, you can bottom the forks.