Bond Bug ZZR1400 Project



Alternator upgrade- NOW FINISHED

Finished project has now been black anodised by the specialist company making the new outrigger bearing, custom pully and belt system.

The new Kawasaki ZZR 1400 engine has an internal alternator outputting only 38 amps in a counter clockwise direction. No upgrading to the existing windings is possible.

I am going to drive a new CCW 170amp Delco Remy high output alternator by extending the existing crankshaft through a bearing housing. The existing Kawa rotor and windings have been removed.


A specialist engineering company has builts the new shaft extension , bearing housing, two new pulleys at a 1 to 0.9 ratio and the engine mounting plate with adjuster. A serpentine belt will be used to transfer the power.

The downsize in the pully ratio is to allow the 12,000 rpm engine to drive the alternator that has a max rev of 10,000 prm.

The new alternator is brush less and provides 100 amp at idle. More than enough to power all the ancillaries.

Alternator connections

NEW external 170 amp now finally fitted to the crank shaft. All the main wiring tucked nicely behind alternator mount.

Finished alternator now assembled

New alternator finally finished - aluminium prior to black anodised finish


Alternator loosely mounted with belt position

New pulley with added edges to prevent belt run off.


New plate being machined for crank extension bearing

Bearing plate machined

Alternator mount plate loosly fitted on the engine

Existing alternator cover



Existing alternator removed


Existing tapered fitting to the end of crankshaft for extension

Positioning of new alternator

Part No. 8600126 — 36SI New Alternator

Specifications-performance Output12 Volts 170 Amps (100 Amps at Idle)

24 Volts 105 Amps

Maximum Speed 10,000 RPM Continuous 12,000 RPM

Intermittent Rotation Clockwise or Counterclockwise

Temperature Rating125°C/257°F

MountingJ180 Short Hinge Mount Quad Mount Pad Mount


Weight25.4 lbs/11.5 kg

36SI™ Heavy Duty Alternator

FEATURES & BENEFITS Brush less Advantage: fewer moving parts means less wear and longer life Equipped with Remote Sense which can reduce battery charge time by 50%