Electrical question


Information and questions on GL1200 Goldwings (1984-1987)
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Yosemite Sam
Posts: 19
Joined: Tue Apr 03, 2012 4:23 pm
Location: Painesville, Ohio
Motorcycle: 1985 GL1200 Interstate

Electrical question

Postby Yosemite Sam » Sun Apr 15, 2012 6:14 pm



Hello all, newbie here hoping I can get some help. I just bought an 85 GL1200 Interstate, and giving it some well needed TLC. While working on getting it to idle, I noticed some wires getting pretty hot and smoking, looking closer I see the wires connect between the harness and the starter moter (looks like to me), you can see the white connector is melting. I looked in the shop manual and at online parts fiche, and can' find what it is called to get a new one, so I'm hoping ya'll can help me out. Please see pic below, I'm hoping to get this ol' girl on the road asap....thanks!

Take care,
Sam



_______________________
Proud to have served, USN 82-92
USS England CG-22
USS Duluth LPD-6
USS Downes FF-1070
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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Electrical question

Postby seabee_ » Sun Apr 15, 2012 8:23 pm

That connector is a known problem with the 1200's. Cut the connector out, get some wire the same gauge, then solder and heat shrink it together. Do a search on this forum or look in the how to section for a tutorial on this. Get it done soon or you risk frying the alternator. It is an easy fix. Good that you caught it in time. And welcome to the forum.
I have a link bookmarked at home on how to do this. I'll try and post it when I get home.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

User avatar
seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Electrical question

Postby seabee_ » Sun Apr 15, 2012 11:04 pm

Here is that link I promised you. Hope it works for you.
http://www.goldwingfacts.com/forums/forum1/112088.html
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

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thrasherg
Posts: 1837
Joined: Tue Oct 20, 2009 11:21 am
Location: Plano, TX
Motorcycle: 2004 GL1800, 2005 Honda Shadow 750, 2008 Yamaha R6 with RG500 engine, CRF450X, CRF230, CRF250X, XR200, CR500

Re: Electrical question

Postby thrasherg » Mon Apr 16, 2012 12:22 pm

As stated, that is the connector between the alternator and the regulator/rectifier unit. It is a well known weakness, the plug corrodes and then due to the large currents flowing, the connectors heat up and melt and either cause the electrics to fail or catch fire. You need to remove the connector completely and solder the wires together, as they are AC any of the top 3 wires can go to any of the 3 lower wires, you just need all 3 wires to be well connected and then insulated so they don't short together.

I would use heat shrink tubing, solder the wires together and then slip heat shrink tubing over the top and that should then prevent shorts and keep any water out so there is no further corrosion.

Gary

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SilverDave
Posts: 367
Joined: Sun Aug 09, 2009 9:39 am
Location: Langley, BC
Motorcycle: 1985 GL1200 GoldWing Aspy

Re: Electrical question

Postby SilverDave » Mon Apr 16, 2012 1:49 pm

But before you solder them back together, when the wires are cut, do the GL1200 Three part test on the stator :
If it passes, you are good to go for many years..
and sadly , if it "fails" you have to think about:
Either a new internal stator :
12 to 15 hours work and $135 + reg/rect , maybe.....

Or External, easily replacable alternator (Poorboy): about 8 hours and $350 first time and mere minutes the second and third times.

-------------------------------------------------------------------------
Three Part Stator Test:

First, put the bike on the center stand and cut the three yellow wires (A, B, C), and strip them back (1/2 inch)

Part 1:
With a multimeter set on resistance, check each leg to ground for shorts.
(Infinite resistance) Zero resistance means a shorted coil in Stator

Part 2:
With the meter set to read resistance, check resistance across each leg. A to B, B to C, then C to A.
Each should be about 3 ohm's. Infinite resistance means an open winding and dead stator.

Part 3:
Start the bike, warm it up, Set meter on AC voltage NOT DC voltage.
When it’s warmed up, clip meter to a pair of yellow wire legs.
With the bike at 3000rpm, check leg A to B. then B to C. then A to C.

Compare the three readings. They should be close and between 50-70vac plus or minus about 5vac per leg.


---------------------------------------------------------------------------------------
and :
As long as you have your soldering gun out, and the shrink wrap...
I can HIGHLY recommend the EC GL1200 harness: all of the iffy connections replaced,
double fused, larger gauge wire (smaller?? well ... BIGGER wire), and hot wires going to the coils, too.

http://www.electricalconnection.com/wir ... charge.htm


SilverDave

User avatar
Yosemite Sam
Posts: 19
Joined: Tue Apr 03, 2012 4:23 pm
Location: Painesville, Ohio
Motorcycle: 1985 GL1200 Interstate

Re: Electrical question

Postby Yosemite Sam » Mon Apr 16, 2012 11:33 pm

Awesome info...thank you very much! This looks to be a good forum, I'm glad I was turned on to it and I'm looking forward to making some new friends. Hopefully I'll be able to help out a few people down the road as well.

Aslo, to seabee_, I'm a Navy vet too, I was in from 1982-92, my rate was EW2. They no longer have an EW rate, they've been combined with CT's.

Thanks again everyone!!!
Sam
_______________________
Proud to have served, USN 82-92
USS England CG-22
USS Duluth LPD-6
USS Downes FF-1070
NAS Miramar, San Diego (TopGun) - Shore duty

alrider
Posts: 1
Joined: Tue Apr 24, 2012 9:32 pm
Location: new market Alabama
Motorcycle: 1986 honda aspencade
1994 honda 1500 interstate
1993 concourse

Re: Electrical question

Postby alrider » Tue Apr 24, 2012 9:57 pm

hey everbody i justs sign on tonight i just purchase 1986 honda aspencade that needs a lot of electrical work nothing major just running lights and wires that are the orignals are there any good manuals that i can get on line or through goldwingsdocs or other sites thank you for any info




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