Three yellow wire question


Information and questions on GL1100 Goldwings (1980-1983)
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littlebeaver
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Three yellow wire question

Postby littlebeaver » Wed Jan 12, 2011 4:08 pm



Ok,[81 gl I] we have learned how to fix the wire plug problem, and even replace with a new plug but I'm considering replacing those tired old yellow wires that have been to hell and back, My question gentlemen[and women] is how are the yellow wire's fastened in the alternator, are they soldered? Bolt and screw connections what, I have not been in there yet, my plan if possible is to replace them with no breaks in the line, the wires are removable at the regulator plug aren't they? To some that might seem like a pain to remove to others having a direct line with no breaks or plugs might be what they want and worth it, how often do you remove the engine anyway? So please how are they connected in the alternator?Thank's Littlebeaver



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WingAdmin
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Re: Three yellow wire question

Postby WingAdmin » Wed Jan 12, 2011 4:59 pm

From what I can see, the three yellow wires pass through a potted grommet (to prevent oil leaks), are surrounded by a heatproof sheath, and are then soldered directly to the windings. Not the easiest thing to replace, and would involve removing the engine.

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virgilmobile
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Re: Three yellow wire question

Postby virgilmobile » Wed Jan 12, 2011 5:07 pm

I would tend to think that the wires are welded to the stator windings(copper to copper).Scrape the joint to verify.Solder has a tendency to crystallize after many heat/cool cycles.

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Wed Jan 12, 2011 5:13 pm

Thank you sir, you see what I was after Right, I have the Will and I know there's a way..Let's do it.. :D Get it done like that guy' says..I need a stator in front of me and I will make it work but I won't mess with my good one, off the bike..So I'm on the hunt for a bad stator..Too play with.. :D if all that expoxy does is act as a seal then I could just drill out three new holes for the new wires, and reseal with JB WELD..Think it will work.? Really you can't get it out just with the swingarm gone?

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Re: Three yellow wire question

Postby WingAdmin » Wed Jan 12, 2011 10:33 pm

littlebeaver wrote:Thank you sir, you see what I was after Right, I have the Will and I know there's a way..Let's do it.. :D Get it done like that guy' says..I need a stator in front of me and I will make it work but I won't mess with my good one, off the bike..So I'm on the hunt for a bad stator..Too play with.. :D if all that expoxy does is act as a seal then I could just drill out three new holes for the new wires, and reseal with JB WELD..Think it will work.? Really you can't get it out just with the swingarm gone?


I'm not sure - perhaps if the motor mounts were removed and the engine moved to one side a bit...but I haven't tried, so I can't say for sure.

I've thought a few times of what would happen if the magnets inside the engine were swapped out with high-flux modern neodymium magnets, replace the stator coils with brand new hand-wrapped coils using high-quality copper, put in some thicker gauge yellow wires, an upgraded rectifier - I bet you could get a LOT more power out of it than you do now.

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RoadRogue
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Re: Three yellow wire question

Postby RoadRogue » Wed Jan 12, 2011 11:21 pm

seems like a lot more work and expense than a car alternator add on.I did my 82 aspy ,55amps. Now I have juice to spare .Just ask me how
Ride safe, Todd
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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Thu Jan 13, 2011 1:26 am

I am wanting to hear any and all idea's, I really enjoy a challenge, any special solder I should use, like silver for electrial or what, I really am unsure..Should I use the flux method with a small propane torch..Has anyone performed this change before, I want new wire's and once I get a idea I usually always make it work..If the engine needs to be moved I will move it..It's winter and a great time to work on this type of thing..I like the idea that you can change stuff too..I love mods...and figuring them out..

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Thu Jan 13, 2011 1:27 am

RoadRogue wrote:seems like a lot more work and expense than a car alternator add on.I did my 82 aspy ,55amps. Now I have juice to spare .Just ask me how

How did you do your Mod. friend.. :D I'm all ear's and I love cool idea's..alot

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RBGERSON
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Re: Three yellow wire question

Postby RBGERSON » Thu Jan 13, 2011 8:49 am

It's called the poor kit..requires adding a pulley to the front crank, drilling hole in the front cases, adding a bracket on the 2/4 side of the engine up front and tucking an alternate up there..a small one like from a GEO.. Several how's on other sites.

the old stator is then dead weight although some leave in as a spare..
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Re: Three yellow wire question

Postby virgilmobile » Thu Jan 13, 2011 9:09 am

If you do solder new wires to the stator,by all means use silver solder,solder paste,propane torch and a bit larger wire gauge(carries more current,less heat).Make the joint overlap for as much physical contact as possible.It would be best to copper weld the wire to the stator if possible but it takes more heat than a propane torch and a different technique.here is a test using #12 solid and stranded I believe would withstand the engine conditions.I Paste coated the wires,wrapped then soldered with a propane torch.Pix attached.Virgil
Attachments

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RoadRogue
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Re: Three yellow wire question

Postby RoadRogue » Thu Jan 13, 2011 10:49 pm

Here is the how to article I wrote up,with pics and posted at Steve Saunders Goldwing Forums (Goldwingfacts.com)

http://www.goldwingfacts.com/forums/forum1/93366.html

I have some 16,000 miles on my conversion with NO problems at all.
Ride safe, Todd
Over night campers welcome

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Re: Three yellow wire question

Postby WingAdmin » Fri Jan 14, 2011 11:55 am

Do you see any issues on the fairing where it contacts the alternator, or does it not get hot enough to worry about?

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Re: Three yellow wire question

Postby littlebeaver » Fri Jan 14, 2011 12:37 pm

Yes sir, I've read about the exterior mod. I'm wanting to mod the existing stator, more like what WingAdmin. is talking about changing the magnets or rebuilding it, Is there a aftermarket stator we could use to replace the original one or upgrade it..?

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Fri Jan 14, 2011 12:52 pm

RoadRogue wrote:Here is the how to article I wrote up,with pics and posted at Steve Saunders Goldwing Forums (Goldwingfacts.com)

http://www.goldwingfacts.com/forums/forum1/93366.html

I have some 16,000 miles on my conversion with NO problems at all.

And it's also an easy repair if you ever do, I like it, but I'm just not sure if I want to go that route yet..

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Fri Jan 14, 2011 6:39 pm

I was also gonna ask about the gauge of the wire, I naturally wanted a larger wire thinking that would be better, but someone else on a another site said not to use larger wire, I need to know about this guy's, can I use a larger wire or what...

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Re: Three yellow wire question

Postby WingAdmin » Fri Jan 14, 2011 7:15 pm

Using a wire that is too large will do nothing except take up more room (because the wire is bigger).

Using a wire that is too small on the other hand will generate heat, resistance and can cause damage and fire.

Basically there is no such thing as "too large" when talking about carrying power. :)

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Fri Jan 14, 2011 7:34 pm

I trust you WingAdmin. I'm not going to listen to the other guy, thanks, I thought that was the case.

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Re: Three yellow wire question

Postby thrasherg » Fri Jan 14, 2011 9:43 pm

Wingadmin is right on the money, there is no such thing as a wire that is too big, beyond a certain size the advantages are very small, but a wire that is too small will have very bad effects on the electric system. Use the biggest wire you can get in there..

Gary

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littlebeaver
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Re: Three yellow wire question

Postby littlebeaver » Fri Jan 14, 2011 10:03 pm

Now you guy's know why I asked because I suggested using a larger wire only to get shot down and I felt foolish for posting the idea and suggesting such a thing.. Man...

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RoadRogue
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Re: Three yellow wire question

Postby RoadRogue » Sat Jan 15, 2011 2:13 am

WingAdmin wrote:Do you see any issues on the fairing where it contacts the alternator, or does it not get hot enough to worry about?




Havent noticed any effect of heat anywhere yet (no warping of the lowers). Will remove the whole fairing this weekend and have a close look at the entire area. Im not anticipating any issues as the fairing is still a fair distance away from the alternator,closest point is the fairing lower.will get back to you on the results of inspection.
Ride safe, Todd
Over night campers welcome

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Re: Three yellow wire question

Postby littlebeaver » Sat Jan 15, 2011 12:59 pm

I only have one problem with the location and it's because it's right where the timing marks are, I have a different way to check my timing with a timing light and that's gonna be in my way, checking it thru the site hole with the light is a pain..I like the pulley method.. :D I found a replacment stator that claims to produce 20% more juice for 130 [rectifier regulator.com ] bones, I am not experiencing any problem at this time but I was covering my bases..Thank's Let me know on the heat..Ya never know, I still may go that route.. :D Thank's on the solder tips, you guy's are gonna make a mechanic out of me one day

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Re: Three yellow wire question

Postby RoadRogue » Sat Jan 15, 2011 11:58 pm

I just came in from the man cave after pulling the fairing off and I took a real close look to see if there was any heat damage in the area of the new alternator,it checked out just fine.Looks like the day I installed it.No warps ,no discoloured paint nothing.the belt still looks new.


Ride safe, Todd
Over night campers welcome


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