Steamer Alternator Swap

[fishnbiker]

Many moons ago there were some comments about using the alternator out of a Kawasaki Concourse for more out put. While doing maintenance on mine I decided to try the swap. I'm finding the driven sprocket on the rubber cush drive won't come off. It moves 1 or2 mm then hits a solid stop. Slightly differing sprocket dimensions seem to need changing out the Concourse drive to the Tiger size.

Any suggestions to do or is it needed??

Thanks, Ken

[fishnbiker]

Update; these alternators are identical physical measurements, except for the drive sprockets. Just trying to learn how to remove & swap for the other.

The Councours unit on the left puts out 400w, 120w more than the OEM Tiger. If I can fit it.

Thanks, Ken

[Nick Calne]

Keep going.

[ssevy]

That is a different swap than the one I remember, as the housings were not the same.
Pretty exciting to think that such an easy swap might be possible.
I have a great old shop in my area that rebuilds electric motors and sells starters, etc. (where I got my Denso starters for 1/5 of what Triumph sells them for), and I would encourage you to try to find a similar one in your area, as they can probably give you all the info about removing that drive.
If you don't have such a place in your area, maybe find the concours forum and post on there?
Good luck!

PS- I thought housing size was the limiting factor for output, as only so many wraps of copper could fit in a particular space, but if those output numbers are accurate, then Triumph could have done it, too. I wonder if it was price point, or some other engineering consideration that made them not do it?

[Beernard]

Great initiative, Fisho,
Keep us posted.

[fishnbiker]

Still digging on this question. I found this article from TriumphRat inmate N5XL ...

https://www.triumphrat.net/threads/dissecting-the-nd-25-amp-alternator.134079/

The Kawi units are interchangeable once the drive sprocket is exchanged for the Triumph one.

Seems I need some heat. More to come ...

[fishnbiker]

So I got the drive sprocket removed with the assistance of a propane torch to soften the resin glue & it pulled off easily. A quick clean & paint job. It's now on the bike awaiting testing once I finish rebuilding everything else.

[ssevy]

Did it feel much heavier than the original?
All of that extra copper wire should have made a difference?

[bemusedinsojo]

What year Concours?

[fishnbiker]

I didn't even think about the weight. All installed now & not coming out again.

Concourse Year should be similar to the Steamers. I got this as a spare many years ago, so have no tracking on it now

[bemusedinsojo]

How is the alternator working? Any tips or tricks?

[bemusedinsojo]

I read the article you referenced. What a great idea. I am really interested in doing this.

[fishnbiker]

How is the alternator working?

Any tips or tricks?

Not yet know as the bike is undergoing restoration with a couple of months still to start up.

The Cush drive change out requires heating to melt out the epoxy glue holding it in place after the bolt is removed.