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 GL-1800 Alternator Removal
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fewheeler

10 Posts

Posted - 03/14/2010 :  01:11:30 AM  Show Profile  Visit fewheeler's Homepage  Send fewheeler a Yahoo! Message  Reply with Quote
I do not know about the starter, but this is what we did to get out my alternator.
After removing the side cover.
1. Remove battery.
2. Remove battery box.
3. Remove only the screws that hold the fuse panel
4. Now take a 3/8 extension 15" long with a 12mm swivel socket or a 12mm socket attached to a universal. Do not put swivel at socket end but between extensions, it's easier to fish through.
5. This is the tricky part, you have to manuver the extension with the socket from as close to the the fuel tank as possible. Keep moving it toward the rear bolt of the alternator.
While one of you is doing this the other is moving hoses and wiring away from the path of the socket.
6. By this point you will have to add a 6" extension onto the end that you are using to push the other extension foreward with. ( the reason being is that there is not sufficient room to put one long extension into place because of the tight area.)
7. Now while one of you moves the extensions toward the rear bolt on the alternator, the other is using a 12" flat blade screwdriver to position the socket onto the bolt. Then just put the ratchet onto the extension and back out the bolt. A magnet will help hold bolt while removing after unbolted from frame. It took us a while to get it figured out but this way definitely works.
More so, this way takes about 45 mins. to 1 hour max.
The other two bolts are readily accessible. The bottom bolt takes time to remove as it is in a position where you can only turn one flat of the bolt at a time.
Of course unbolt the hot wire and now you just gently move the alternator towards the rear of the bike, as it slides out of the spline coupling. Then roll it out where you can more easily unsnap the green connector and you're done

Freddy & Doris Wheeler
Former Motorist Awaness Division
Alabama District Coordinator
Gold Wing Road Riders Assn.
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