HOT voltage regulator


Information and questions on GL1100 Goldwings (1980-1983)
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kc0zjk
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Location: Osborn, Mo.
Motorcycle: 1980 GL 1100 Interstate
1982 GL 1100 Interstate

HOT voltage regulator

Postby kc0zjk » Sun Jun 26, 2011 9:51 pm



1980 GL100 I have tried 3 different regulators and tried all grounds I can find .. also have added ground wires from battery to frame-engine-and on the regulator bolt .. stator puts out 38-45 volts ac .. I have direct wired the yellow wire plug .. power only about 12.0-12.3 depending on if I charged the battery nite before .. any input is helpful .. I've cleaned all connections and even changed the diode in line .. thanks



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WingAdmin
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1998 XV250 Virago (sold)
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Re: HOT voltage regulator

Postby WingAdmin » Sun Jun 26, 2011 10:05 pm

It's supposed to be hot. Really hot. Burn your hand hot.

The GL1100 (and GL1000 and GL1200) use a stator, instead of an alternator. The stator puts out FULL POWER at all times. If you're spinning the engine at 3,000 RPM, the stator is putting out every watt it is capable of generating.

Your bike only needs so much power. After powering the engine, lights, accessories and charging the battery, there is unused power generated by the stator that the bike doesn't need. You can't just "get rid of it" - it has to go somewhere. So the regulator simply shunts it to ground. In doing so, it converts this extra power into - you guessed it - heat.

So don't worry about it. The fact that the regulator is hot means that it's doing its job correctly, and that everything is working as it should.

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kc0zjk
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Joined: Mon May 31, 2010 8:52 am
Location: Osborn, Mo.
Motorcycle: 1980 GL 1100 Interstate
1982 GL 1100 Interstate

Re: HOT voltage regulator

Postby kc0zjk » Sun Jun 26, 2011 10:26 pm

Ok .. heat is normal .. thanks for clearing that up ... what about the low voltage .. is it normal for that low .. have an aftermarket digital gauge .. the voltage gradually drops on longer rides ... battery checks out good .. only have headlite turn/marker and stop/turn/tail .. standard bulb .. have some LED lites on the back .. no where near what was on originally .. also changed to a standard starter solenoid .. 30A fuse in the red lines .. hooked to the + term on the solenoid .. any issues come to mind with the solenoid change .. thanks

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virgilmobile
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84 GL 1200 I

Re: HOT voltage regulator

Postby virgilmobile » Mon Jun 27, 2011 8:05 am

Is the "12-12.3 " with the engine running at 3000 rpm? or off?
Idle voltage can be less than engine off voltage(the bike draws about 10 amp)and not increase until it reaches 1500 rpm.Fast idle is considered 2500-3000 rpm.
Remember that the charging system is rated at 300 watt at 5000 rpm.It peaks at 25 amp.If the bike draws 10 amp to run it,then there is 15 amp left over to dump into the battery.This all at 5000 rpm.(by the spec sheet).
Voltages at the battery will vary depending on rpm and should vary slowly.11vdc to 14.8vdc.900-3000rpm.
Charge rate in amps will also change.On both my 1100 and 1200,after cranking and at 3000 rpm they will charge the battery at near 10 amp and drop to about 2 amp in 3-4 minutes.Both discharge near 2 amp at a idle,and return to charging above 1100 rpm.

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dingdong
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Re: HOT voltage regulator

Postby dingdong » Mon Jun 27, 2011 8:24 am

I would still be looking at the battery. A battery that "checks out good" may not hold up under load.
Tom

A well regulated Militia, being necessary to the security of a free State, the right of the people to keep and bear Arms, shall not be infringed.

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kc0zjk
Posts: 4
Joined: Mon May 31, 2010 8:52 am
Location: Osborn, Mo.
Motorcycle: 1980 GL 1100 Interstate
1982 GL 1100 Interstate

Re: HOT voltage regulator

Postby kc0zjk » Thu Jul 14, 2011 9:37 pm

changed battery .. put a larger automotive battery in the left side bag .. seems to be better but still not charging to full capacity ... 12.3 is what my meeter reads at hiway speeds .. 4800 - 5000 rpm .. found a small internally regulated alternator .. gonna try the modification .. looks reasonably pain in the ass .. but think it can be done .. I pull a trailer and I think I need the extra boost ... thanks for all the advice and input .. it is very helpful and appreciated .. thanks again .. Jason

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virgilmobile
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Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: HOT voltage regulator

Postby virgilmobile » Fri Jul 15, 2011 9:28 am

It really sounds like a wiring problem.I would be very concerned that replacing the charging system won't fix this.The stator works,you said so.The regulator gets very warm,that's good also,that means at least 2 yellow wires are hooked to it.

Before you leap into a modification,lets look one more time.

You mentioned that the volt meter shows 12.3 volts at 4800-5000 rpm highway.not charging at all.
If you can,test it like this....Using a DVM and the battery post for the ground,measure the battery volts with the bike off.Expect 12.5 volts or so.
Turn the key ON,it should drop about 0.5 volt.
Start the bike and hold the rpm around 2500.It should start to increase above 13 volts.
If it doesn't,Probe either red/white wire at the regulator.
if the voltage there is higher by 0.5 volts,the wiring to the battery is bad from there to the main fuse. Look at the schematic,there are 2 wires to hook to the fuse besides the battery connection.
if the voltage is the same or lower,the stator MAY be bad,or the regulator.
The stator can be tested 3 ways.Ohm it out,Voltage test between each pair of the 3 yellow wires.And a clamp on amp meter.
If you measure for volts look at the pix for what to see.
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