'84 Aspencade -- Major Electrical Short


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Gkopriva
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'84 Aspencade -- Major Electrical Short

Postby Gkopriva » Thu Jun 27, 2013 9:59 am



Hi everyone,

Well I've done it again. Took the bike out for a ride and all was fine -- all electronics working perfectly. Park the bike in the garage, come back a week later to take her out and nothing. no lights/ no power. I check the battery -- fully charged. All fuses in the gas tank good. Then I check the 30amp at the starter relay -- sure enough- it's blown. I get a new fuse and insert it and "pop" it blows the fuse as soon as it touches.

Does anyone have any ideas as to determine the best course of action to take to find what might be causing this to blow ?? I mean it's blowing the fuse before I even insert the key into the ignition.

Thanks in advance for everyone's ideas!!



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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Thu Jun 27, 2013 10:43 am

Unplug the voltage regulator module...It's the most likley cause...

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Thu Jun 27, 2013 2:24 pm

:) Assuming I find the voltage regulator will this need to be replaced or will the bike function without it being plugged in? I know where the starter relay is and changed that out with a new one figuring that may be the cause.

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Thu Jun 27, 2013 2:40 pm

First,the regulator is just to the left of the air cleaner under the top cover.It has a large plug with 8 wires in it.It's about 3" square with cooling fins.Unplugged,the bike will run but obviously not charge the battery.
The solenoid has 2 large red wires,they connect to the 30 amp fuse.Any short on that wire will pop the fuse.The regulator and key switch are the only 2 things attached to them.
So if your 30 amp fuse pops with the key off,either the red wires are pinched to the frame and shorting out or the regulator module is shorted.
Check it out and let us know what you find.Take pictures too.
If the regulator is bad,you will want to examine the other parts of the charging system before just sticking in another one.

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Gkopriva
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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Thu Jun 27, 2013 9:31 pm

Thanks for the information. I'll check it out this weekend!!

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sat Jul 20, 2013 6:15 pm

Well, getting back to the bike to longer than I thought .. did a test on the voltage regulator today by disconnecting it at the connector... put in a new fuse and pop! so looks like I need to hunt down a short in one of the wires. Hopefully I will find this quick!!

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 1:27 pm

Ok, I've located the wire that is causing the short --- it is the wire from the starter relay (red with white stripe and is located in position 4 below:

FUSE
wire 4 wire 3
wire 2 wire 1

I've disconnected this wire from the starter relay and the bike starts up fine. I have the seat off and none of the wires looked pinched or open. Does anyone know where this wire leads?

Thanks,

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 1:46 pm

By your description of it starting fine,that wire must go to the regulator module.
As I recall ,the 2 red wires that leave the regulator plug are joined together in the harness and go to the solenoid.You should be able to split the harness open to isolate that wire.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 1:58 pm

Thanks, will I need to unwrap the whole harness? it joins up with another group of wires under the seat...

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 2:09 pm

If your certain that the regulator is unplugged and its not the problem I'd start right at the unhooked red wire and split the wrap with a knife.It can be wire tied back secure.
That shorted wire can be extracted from the harness and repaired.Take pictures.Its unusual to have a bad wire inside the harness unless its pinched under a bolt.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 3:28 pm

I found where I think the problem is. the red/white wire goes to the charger plastic connection. When I looked closer I noticed two small gauge wires (green and red) that appear to be coming from where the red/white wire goes in to the connector and where a green wire goes in. The two small wires connect to a stand alone piece that has a rubber cover on it --- I would describe it as two dime sized cylanders about an inch or two long inside this rubber casing.... as I peel back the wrapping of the two small wires it appears as these wires melted together which is causing the short.... any idea what this item is??

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 4:12 pm



My description may have been less helpful but here are pics of the item I believe is causing me a problem. Is this a capacitor? Can it be replaced? the wires looked like they got real hot and melted ... I separated them but as you can see I've got a lot of open wires...

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 4:55 pm

Remove the offending part.Its not original.Id guess,someone added a couple of noise filter capacitors and they were not rated for the voltage spikes.As far as I remember,there's only 8 wireds from the harness to the regulator plug.
2 large red.battery
3 yellow stator
2 green ground
1 black/green switched ignition.

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 5:05 pm

At least my 6 wings didn't have this,maybe yours did for some reason.Either way they need to be removed.If you feel they need replacing for noise reduction for some electronic equipment on the bike,the rating of the caps should be right on the casing.Id just tripe the voltage capacity.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 5:10 pm

Thanks sooo much!! Cut that puppy off and plugged the one red/white wire back into the starter relay and no fuse popped --- bike started right up!

Mystery solved!

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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 6:12 pm

Now,use a volt meter and check the voltage directly on the battery posts.It should be 13.2-14.4 volts depending on the RPM.
Measure after the bikes been running for a few minutes.
We're mostly concerned about it being above 14.8 volts at 3000 rpm or not charging at all.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 6:43 pm

Ran the test, and only getting 12.05 on the meter at 3000 rpm...

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 7:09 pm

If that's direct on the battery posts,the battery isn't being charged.
Check the little black wire on the regulator.Its suppose to have switched 12 volts.It gets the regulator running.
The parts you removed should not have any affect on the charging system.
It's really simple.3 yellow stator wires.2 grounds.2red charging wires and the switched black wire.
Something's unhooked.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Sun Jul 21, 2013 9:05 pm

ok, thanks, I'll dig into it this week -- worse case next weekend -- hopefully this will be an easier issue to detect. and yes, my meter was right on the battery posts. sounds like I'll be on the follow the black wire project. is the black wire simply a ground or does it require something else to activate it for charging

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virgilmobile
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84 GL 1200 I

Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Sun Jul 21, 2013 9:23 pm

On the wings,green is the only ground.Black is either 12 volts continuous or switched 12 volts.
The regulator is the same.The little black wire with the trace is switched 12 volts.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Thu Jul 25, 2013 5:30 pm

ok, I got the meter on the black wire at the plastic connector of the regulator and it is registering 11.22 +- with the engine running. with the ignition switch on and the engine off I am still getting a reading. I did check all the fuses in the fuse box and all were fine.

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virgilmobile
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Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Thu Jul 25, 2013 5:58 pm

Unplug the regulator and measure the wire on the harness.its suppose to be switched 12 volts

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Thu Jul 25, 2013 6:53 pm

ok, I separated the connector and tested both ends with the ignition ON. As you would expect, I get 0 from the black wire going to the regulator but I know get 10.7 volts from the other end of the connector. (I believe my battery is slowly draining). With the ignition set to off not current is found. I plugged the connector back together and checked all connection points. all showed current passing through any connector points.

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virgilmobile
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83 GL1100 I
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84 GL 1200 I

Re: '84 Aspencade -- Major Electrical Short

Postby virgilmobile » Thu Jul 25, 2013 8:25 pm

There's only 2 things left.Either the stator or regulator pooped out.
If there is about 25 volts AC...between any pair of yellow wires at 1000 rpm,the stator is probably ok.When unplugged from the regulator.
Do measure all 3 wires.Its 3 phase AC. Do not measure to ground.
This is assuming the regulator grounds are OK too.

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Re: '84 Aspencade -- Major Electrical Short

Postby Gkopriva » Fri Aug 02, 2013 8:04 am

Well, I finallygot to it this weekend and was getting mixed numbers on my meter -- (more likely I was not tapping the correct wires under the right scenerio) as it looks as if some previous owner removed connectors. At any rate, I rode over to my local Honda dealer who put it through a charging test and low and behold -- the stator is fine, the voltage regulator was toast. A new one was ordered and we are back in business! Thanks soo much for your help.




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