GT750 alternator upgrades

All to do with wiring, charging or just trying to figure out whats gone wrong.

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Suzsmokeyallan
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GT750 alternator upgrades

Post by Suzsmokeyallan »

The four wires from the alternator on the GT750 are a little on the small side and after 30 plus years their condition and the sheathing over them is usually due for an update.
Taking them up to 14 gauge size is an added plus while fitting new sheathing to the harness and making a new socket at the electrical panel.
Once you open the flat clamp and slide off the sheathing on the alternator body you will see the three yellow wire ends by the clamp are a crimped barrel fitting and soldered to the three phase windings.
Since those barrel fittings are not easily available you can use a female bullet fitting and alter it for the wire connection, then solder it in and place heat shrink tubing over the completed joints.
You have to work neatly here, as the new wires and joints are bigger and so if you make lumpy joints the three wires will not fit back into the stock clamp.
Here's how it all played out in photos for this minor update on the three coil to wire joints.

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One of the original barrel fittings un-soldered from its coil wire.

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A stock female bullet terminal to be altered for the new crimp.

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The terminal now altered for the job at hand.

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After dividing the wires on each side and placing the coil wire in the middle of them, the joint gets crimped.

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Then a little solder is flowed into the opening of the crimp, you cannot create lumps, it has to be neat. If your joint is bigger than the 14 gauge wires casing you will not get them all back in the stock clamp.

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Here's the end result with some new heat shrink tubing over each phase wire and a larger one over the three wires creating a factory look.
Not shown is the upgraded green wire, new sheathing and the new socket at the panel end.
Two strokes, its just that simple.

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