Three yellow wires


Information and questions on GL1100 Goldwings (1980-1983)
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WingAdmin
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Three yellow wires

Postby WingAdmin » Tue Jan 06, 2009 4:38 pm



As is fairly common knowledge, the plastic connector that connects the stator to the voltage regulator tends to heat up over time, until it causes a catastrophic failure. If you haven't replaced this connector yet, now is the time.



Cut out the connector and replace it with directly soldered wires. Each yellow wire coming from the stator at the bottom of the engine should be connected to a yellow wire that runs to the rectifier. Strip and twist the wires together, solder them, and cover with heat-shrink tubing. It doesn't matter which yellow wire is connected to which - as long as each of the three wires coming from the stator is connected to one of the wires going to the rectifier.

I looked at mine at the beginning of last spring, and it looked fine. Being that it had been fine for many years, I decided to leave well enough alone. A few months later I looked again, and found this:



Do it before yours look like this!



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Re: Three yellow wires

Postby MSGT-R » Thu May 07, 2009 5:23 pm

A good habit to get into is to check that connector every time you wash the bike. Disconnect it and reconnect it again to keep the contact points fresh and clean. Fill the plug cavity with Silicone Di-electric Grease to keep the moisture and corrosion out of that area! This is a common problem with all 80's era Hondas.
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Re: Three yellow wires

Postby WingAdmin » Thu May 07, 2009 9:01 pm

Really, the best thing to do is to just cut the connector off altogether and solder the wires directly. That way you'll never have to worry about maintaining the connector, or having it go bad and melting wires when you least expect it.

If you do ever need to pull the stator, just cut the wires, then resolder when you reinstall - but how often do you do that? Mine's 30 years old and still on the original stator, so...not often.

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Re: Three yellow wires

Postby Roleketu » Sat Aug 01, 2009 11:08 am

The Electrical Connection has a nice modified wiring harness to help with the small gauge stator wire. See http://www.electricalconnection.com/wire-harnesses/hrns_gl1200_charge.htm

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giffen49
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Re: Three yellow wires

Postby giffen49 » Sun Aug 23, 2009 6:54 pm

I took a look at my connector today and tried to unplug and examine it. The thing was fused together. The wires on the stator side were burnt and brittle and the plug was melted on one side. I soldered the wires.
Thanks for the heads up on this issue.

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Re: Three yellow wires

Postby BladeRunner9 » Sat Aug 29, 2009 11:46 pm

That part from electrical connection seems to be well thought out and just the "fix" to satisfy this issue once and for all!
In fact I ordered one of their kits and by chance my CC was declined...turns out I reversed the expire dates ..duh! :oops:
So, when I ordered I requested surface mail ONLY...I can't see paying $19 for shipping on a small item. They assured me they would send it that way; However, when my card was declined I found out they STILL charged me $19 for shipping!
So, I called and spoke to someone...didn't get his name, he told me they can't ship by "snail-mail" because there are no post offices near them...it's an hr away!
So, he said by the time they send someone there and back it would be more than 2 hrs of their time and besides they "only do their business online". So, I cancelled my order, just WAY too much money for a small package for my liking. But, the product is just the ticket....well thought out, too bad they can't find a post office...guess they never get any mail? :shock: :P

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Re: Three yellow wires

Postby WingAdmin » Sun Aug 30, 2009 10:26 am

BladeRunner9 wrote:So, I called and spoke to someone...didn't get his name, he told me they can't ship by "snail-mail" because there are no post offices near them...it's an hr away!
So, he said by the time they send someone there and back it would be more than 2 hrs of their time and besides they "only do their business online". So, I cancelled my order, just WAY too much money for a small package for my liking. But, the product is just the ticket....well thought out, too bad they can't find a post office...guess they never get any mail? :shock: :P


I think they were lying to you.

First off, they give their address as:

3300 Rifle Range Rd, Suite A, Knoxville, TN, 37918

That sounds pretty urban to me. Then, on their "Contact Us" page, they actually give their GPS coordinates, which on Google Maps looks like:

http://maps.google.com/maps?sll=36.0569 ... 27320&z=18

An industrial park, right smack in the middle of the largest city in Tennessee. I highly doubt a post office is more than hour away from an industrial park. At most maybe 5-10 minutes.

However, the main thing is, here in the US, when your mail is delivered....they also pick up outgoing mail! So all they would have to do is package it up and give it to the mailman when he delivers the mail!

It looks like a good product, but if that's what they told you, I would be suspicious of them. I don't like vendors who lie to me.

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Re: Three yellow wires

Postby BladeRunner9 » Sun Aug 30, 2009 2:38 pm

I have to agree, I just didn't want to say it. It sounded like a fairy tail to me; :evil:
Unfortunately, they are probably missing out on sales by "making money" on the shipping "internet only" sales they claim. I mean, $50 for the part...then $19 to ship! That's nearly 50% of the price... :roll:
By comparison; I just recieved 3 sets of Kevlar brake pads for my 87A, they came from Florida right to my mail box..I'm certain they could not have weighed less than EC's relay and wiring...yet the shipping was only $11.00. I've noticed some things on Ebay (where I got the pads) have exceptionaly high shipping prices, they get you with reasonable parts prices...then tag you BIG for shipping! I'm new at the ebay thing,but, I'm learning fast what to watch out for!.... :shock:
As I said in a couple of posts; the EC thing looks like a great idea....Too bad they have such high shipping rates.... :?

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Re: Three yellow wires

Postby Roleketu » Mon Aug 31, 2009 7:38 pm

On the EC wiring harness, I didn't look at the shipping as to be high, which it is, but rather the harness cost to me was $69.00. Not only does the harness replace the small gauge wires from the stator, it adds a few other benefits. First, an additional use of a relay, the coils only get power when the ignition is turned on and the coils are now powered directly from the constant battery voltage instead of the variable stator voltage. That makes a direct and immediate difference in the spark plug's spark. Next, replaceable 10amp and 40amp fuses are incorporated to its power supply. Finally, the manufacture is highest grade and they hand solder and heat shrink every connection. Would you feel any better if they charged $69 for the harness and offered "Free Shipping"? I highly recommend this easy upgrade that solves some large defects in a fine motorcycle.

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Re: Three yellow wires

Postby WingAdmin » Mon Aug 31, 2009 8:11 pm

I would look at it this way - a $10 relay, a couple $5 fuse holders, some large gauge wire I already have sitting around, and half an hour with a soldering iron. :)

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Re: Three yellow wires

Postby BladeRunner9 » Mon Aug 31, 2009 8:28 pm

I'm not disputing the value and design of the product, I think it's a great idea and well thought out.
I'm new to e-bay but I'm learing fast!
"Some" things are rather inexpensive..but they TAG you big time on the shipping, makes you wonder if that is where they make their money? To each his own..
I just got a full set of brake pads for my wing.(6 pads) from florida by USPS international in a box..I KNOW they weigh more than a relay and a few wires; shipping right to my mail box..in 5 days $10.89.
Besides, EC claimed the post office is more than an hr away....Do they not get mail at their place of business? Just makes you wonder... :roll:

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Re: Three yellow wires

Postby WingAdmin » Tue Sep 01, 2009 10:20 am

I do a lot of selling on eBay and elsewhere, and from time to time I will have someone complain about shipping costs - they will look at the weight, go to usps.com, and write me something like, "hey, it says there it should cost $4.80, how come you're charging $8.00????" (or whatever).

What they fail to take into consideration is that I have to buy boxes, bubble wrap, peanuts, packing tape, as well as pay for the monthly charge my shipping software charges me. All that stuff costs money - and more often than not, I am actually LOSING money on my shipping/handling charges.

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Re: Three yellow wires

Postby BladeRunner9 » Tue Sep 01, 2009 7:27 pm

Point taken: I still think $19 is over the top for such a small package... :cry:

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Re: Three yellow wires

Postby WingAdmin » Thu Sep 10, 2009 12:07 pm

Here's another picture of a GL1100 melted stator plug that someone sent me.


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Re: Three yellow wires

Postby BladeRunner9 » Fri Sep 11, 2009 4:48 pm

That's from an 1100? I thought this problem was only on the 1200's? Thanks, learn something new every day! :)

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Re: Three yellow wires

Postby WingAdmin » Fri Sep 11, 2009 6:51 pm

Absolutely it happens in the 1100's as well!

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Re: Three yellow wires

Postby rickthehitman71 » Mon Sep 21, 2009 3:18 pm

Hey I just checked mine and found that it is burnt and cracked too so thanks for the heads up. I guess you know what my new project is this weekend. I am in the process of restoring my bike. I will get some pica on the site so that everyone can track her progress. Her name is going operation freedom for she the freedom of my sole.

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Re: Three yellow wires

Postby MSGT-R » Mon Oct 26, 2009 5:03 pm

Absolutely keep close tabs on this connector.!!

My last trip to Sacramento and back (about 800 miles total), had the connector in my V65 Magna melt! It was fine on my pre-trip inspection. I soldered the wires.

I am going to closely watch my GL1100. I have changed that plug once, but that doesn't mean it can't happen again. :(
Don't spook the road sheep.

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Re: Three yellow wires

Postby WingAdmin » Tue Oct 27, 2009 6:31 pm

I had heard about this connector having problems, so I had a look at mine - it was dirty, so I cleaned it out and made it like new, and figured it would be good for a while. A year later, I found the melted, overheated mess you saw on this thread. I cut it out and replaced it with soldered-in wires, and have never had a problem since.

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Re: Three yellow wires

Postby seniorcitizen » Tue Dec 22, 2009 9:36 am

WingAdmin wrote:I would look at it this way - a $10 relay, a couple $5 fuse holders, some large gauge wire I already have sitting around, and half an hour with a soldering iron. :)

Hello, I'm a new member and found this thread very interesting. I would just like to add if you ever do this alternate "$10 dollar relay..etc " please post the pics and I will do it like you suggest. This is a great forum and I'm sure it will come in handy as I plan to maintain my own wing. Cheers !!

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Re: Three yellow wires

Postby Five » Sun Jul 04, 2010 3:11 pm

Did mine today. No external damage was evident, but when I pulled the connector apart, it was melted and one wire burnt. Do it NOW, before it's too late :D
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Re: Three yellow wires

Postby littlebeaver » Tue Sep 28, 2010 8:00 pm

I am no sparky but it would seem that the connections in these plugs are too close together for the current flowing thru there. Can I just use straight connectors and just crimp the wires and tape them up instead of soldering them? My soldering gun in on the blink...

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Re: Three yellow wires

Postby MSGT-R » Wed Sep 29, 2010 8:32 am

Overlap the wires in the butt connectors if possible. Anything to further the connection is always better.
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Re: Three yellow wires

Postby littlebeaver » Wed Sep 29, 2010 10:36 am

Hey it seems like you were reading my mind I did that exactly , I gave it a fold over before crimping it, thanks, It would seem to me that after these wires having lots of current flowing thru them for so long it could weaking them or break them down, Is it wise or possible to replace the wires all together with new wires, or too much of a pain? I want new wiring throughout my whole bike now after seeing that plug... I wanta know whats causing this to start with...Has anyone figured this problem out yet???? I'm gonna leave the connectors on it like that just to see if anything melts, there's a good plastic cover on all three of them.. If it works I will report back if not I will still report back... Would a weak battery or bad ground cause the alternator to work harder thus causing this problem thru the wires???? I ruined a few alternators back in the day on a weak battery..

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Re: Three yellow wires

Postby WingAdmin » Wed Sep 29, 2010 11:42 am

It's caused by insufficient connector size and dirt. I thought, "I'll just clean out my connectors and make sure they're firm, I don't need to cut them out and solder them." A year later I pulled them apart and found them melted. I cut them out and soldered them, and haven't had a problem since.

Using a crimp will work - but I would do so planning on soldering them in the future. Solder keeps the joint from oxidizing, which adds resistance. Crimped connections will oxidize over time, and you'll be right back where you started off. Worst case scenario is that it generates enough heat to light something on fire.




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