1200 electrical


Information and questions on GL1200 Goldwings (1984-1987)
  • Sponsored Links
w4r
Posts: 11
Joined: Wed Aug 10, 2011 9:57 am
Location: bandera, texas
Motorcycle: 1985 GL1200 LIMITED w/sidecar

1200 electrical

Postby w4r » Tue Feb 05, 2013 7:41 pm



I have a 1985 GW limited 1200. I recently replaced my standard acid battery with a new jell(?) filled battery. While doing this I decided to clean and paint the battery holder. On disconnecting the three (3) pole electrical connect (on the left (front) side of the battery case I noticed that it appeared severly burned but still worked. I would like to replace this male/female connector but I am unable to locate a replacement. I believe this is a connector for the stator but not sure. Called dealers with no success.

Any ideas.



User avatar
HALBUDD
Posts: 846
Joined: Sat Aug 14, 2010 9:14 pm
Location: New Albany In
Motorcycle: 1984 gl1200a&1985GL1200A & 1996 gl 1500 aspy. us army 74-77

Re: 1200 electrical

Postby HALBUDD » Tue Feb 05, 2013 9:25 pm

Dont try to replace it cut it out and solider the three wires one on one. Make sure you put heat shrink on the wires before joining them together. The old connectors where a major pain they would burn up or cause poor connection burning up your stator.I would also replace the old dog bone fuse with a new blade type fuse holder. There are some How To Articles on both of this fixes . Good Luck-------------------------Hal
A woman that can use tools is worth her weight in gold !!

User avatar
WingAdmin
Site Admin
Posts: 17046
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: 1200 electrical

Postby WingAdmin » Wed Feb 06, 2013 10:06 pm

This is a very common problem with four-cylinder wings. If you do a search here in the forum for "three yellow wires" you'll find tons of information on it.

jdvorchak
Posts: 39
Joined: Thu Jul 16, 2009 11:58 pm
Location: East Alton, IL
Motorcycle: 2001 GL1800
2000 HD Dyna FXDX
1984 GL1200 STD

Re: 1200 electrical

Postby jdvorchak » Thu Feb 07, 2013 3:30 pm

FYI it doesn't matter which yellow wire is soldered to which. That is AC current output from the stator, which is why they are all the same color.

User avatar
goodoni
Posts: 32
Joined: Fri Jul 13, 2012 12:29 pm
Location: Brighton, Michigan
Motorcycle: 1984 GL1200I Interstate

Re: 1200 electrical

Postby goodoni » Thu Feb 07, 2013 4:05 pm

I agree with HalBudd, cut out the plug and solider in an extension and shrink wrap the wires.
I have an 84 Interstate that had the same problem.
The job only takes about an hour or so, I highly recommend a solidering tourch.
The old style solidering irons take to long to heat up the wires, also with the tourch the solider cover the wires more evenly.
Good luck, ride safe.

Goodoni

gold bobber
Posts: 3
Joined: Sat Apr 20, 2013 7:59 am
Location: Morgantown, West Virginia
Motorcycle: 1984 GL1200Aspencade

Re: 1200 electrical

Postby gold bobber » Sat Apr 20, 2013 9:55 am

The reason that the connector was melted is not caused by a short, it's the extreme heat that the voltage regulator/rectifier generates. This seems to only be a problem on the 1200"s, even the ones with the smaller 350V stators. The stator put's out full power all the time, at idle or wide open, the system is designed to dump the excess voltage as heat to ground, the reg. gets hot enough to burn you. So when you solder and heat shrink the three yellow wires, this will give you a better connection, but the regulator will still get very hot, I found that splicing in some xtra ground wires and grinding of all the paint from the point of connection to frame, that this helps the reg 's heat output some. I replaced the ground wires with braided ground straps, you eliminate to crimp connector's poor contact. If you have to replace it, spend the xtra money and get a top of the line unit, they will not get near as hot as the factory one. They have one's out there that are designed to correct the heat issue.

jdvorchak
Posts: 39
Joined: Thu Jul 16, 2009 11:58 pm
Location: East Alton, IL
Motorcycle: 2001 GL1800
2000 HD Dyna FXDX
1984 GL1200 STD

Re: 1200 electrical

Postby jdvorchak » Sat Apr 20, 2013 11:05 am

I posted a "How To" on the NGW club website with pictures and a little instruction on how to solder.

http://ngwclub.com/forum/viewtopic.php?t=32968

Hope this is helpful.

highplainsbubba
Posts: 12
Joined: Mon May 31, 2010 2:44 pm
Location: Calhan Colorado
Motorcycle: 1986 GL1200 Interstate

Re: 1200 electrical

Postby highplainsbubba » Sun Apr 28, 2013 1:33 pm

When I soldered my 3 yellow wires together, I added a small pigtail wire on each of the three wires and terminated it with a butt splice. Now I have 3 test points that I can put a meter on to see if the alternator is producing voltage. It should read about 12-14 volts AC between each of the three yellow wires. Remember, it is AC at this point because it hasn't been rectified yet. I also added a digital voltmeter and amp meter on the home made blanking plate I put on the dash. They are available on Ebay.

jdvorchak
Posts: 39
Joined: Thu Jul 16, 2009 11:58 pm
Location: East Alton, IL
Motorcycle: 2001 GL1800
2000 HD Dyna FXDX
1984 GL1200 STD

Re: 1200 electrical

Postby jdvorchak » Sun Apr 28, 2013 9:10 pm

highplainsbubba wrote:When I soldered my 3 yellow wires together, I added a small pigtail wire on each of the three wires and terminated it with a butt splice. Now I have 3 test points that I can put a meter on to see if the alternator is producing voltage. It should read about 12-14 volts AC between each of the three yellow wires. Remember, it is AC at this point because it hasn't been rectified yet. I also added a digital voltmeter and amp meter on the home made blanking plate I put on the dash. They are available on Ebay.

Correct me if I'm wrong but at the 3 yellow wires they should read well above 50 VAC at 2500 RPM. I think I remember from 50 to 75 VAC. 12-14 VDC at the battery.

highplainsbubba
Posts: 12
Joined: Mon May 31, 2010 2:44 pm
Location: Calhan Colorado
Motorcycle: 1986 GL1200 Interstate

Re: 1200 electrical

Postby highplainsbubba » Mon May 06, 2013 9:46 am

I checked them again with an AC voltmeter, they are showing between 11 and 14 volts. I remember from the past that I had a 40 volt reading on them before. You are probably right, I think if the stator is not connected to the voltage regulator you will get the higher voltage reading.

jdvorchak
Posts: 39
Joined: Thu Jul 16, 2009 11:58 pm
Location: East Alton, IL
Motorcycle: 2001 GL1800
2000 HD Dyna FXDX
1984 GL1200 STD

Re: 1200 electrical

Postby jdvorchak » Mon May 06, 2013 9:55 pm

highplainsbubba wrote:I checked them again with an AC voltmeter, they are showing between 11 and 14 volts. I remember from the past that I had a 40 volt reading on them before. You are probably right, I think if the stator is not connected to the voltage regulator you will get the higher voltage reading.

Stands to reason with no load, the regulator/recifyer, they would read higher A/C voltage. The real question is what DC reading do you have at the battery with and without the engine running:

Battery:
engine off = 12. 5
engine idle = 13.0 to 13.2 or more (stock lighting. Added lighting accessories could be 12.5 or so)
engine at 2500 RPM = 14.2 or more.
Not over 15VDC. Overcharge condition. Check your grounds!

highplainsbubba
Posts: 12
Joined: Mon May 31, 2010 2:44 pm
Location: Calhan Colorado
Motorcycle: 1986 GL1200 Interstate

Re: 1200 electrical

Postby highplainsbubba » Tue May 07, 2013 12:15 pm

I have the normal voltages on the bike when running. It goes to 14.8 DC max and depending on the battery condition down to slightly under 12. Having a real time indication of the voltage/amps is a big help. When I installed the amp meter, I had to put in an Integrated Circuit that provided an isolated power supply and a shunt that I mounted under the seat. Everything is covered and taped up tight. The volt meter was a pretty simple install.




Return to “GL1200 Information & Questions”




Who is online

Users browsing this forum: MSNbot Media [Bot] and 1 guest