Charging system still not working


Information and questions on GL1200 Goldwings (1984-1987)
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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Charging system still not working

Postby petarm1 » Tue Jul 02, 2013 11:16 am



I hope someone can help. I have been having charging problems since I bought the bike last October. Before it would charge at14.5 volts for about 20 minutes than drop to 10.9. Recently I had the stator and the regulator/rectifier replaced and it worked for about 10 minutes than I lost charge again. This time it stays at around 11 volts.tested the battery. Also noticed that the stator wires get to hot to touch within the first 5 minutes of start up and get hotter as the bike is running. I hope some out there has a solution cause my wife is driving mecrazy as she has no problems with her 80s interstate



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virgilmobile
Posts: 7663
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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: Charging system still not working

Postby virgilmobile » Tue Jul 02, 2013 2:13 pm

You'll have to start from scratch.Besides the bikes wires,there's only 2 parts involved.The stator and R/R module.It must have switched 12volts on the black wire for it to start charging.
Begin with the 3 yellow wire continuity test with the regulator unplugged and test the black wire for switched 12 volts.
Don't assume that either part that was replaced it OK.
Confirm it.
Obviously a wire shorted to the frame will cause problems too.
We can detail troubleshooting procedures if you need.

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Tue Jul 02, 2013 2:27 pm

Thanks. I am questioning the voltage to my black wire. But yes I am going to. Test all the new parts as well

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trike lady
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Location: Butler, PA
Motorcycle: 1993 GL1500 Aspencade with Voyager (Sold)
1983 GL650I SilverWing Interstate

Re: Charging system still not working

Postby trike lady » Tue Jul 02, 2013 7:43 pm

Could the wrong stator and reg/rec been installed?
I knew a gentleman who purchased a 1986 SEi and the original owner had the charging system replaced, it turned out that the shop installed a regular 1200 system not the one for the CFI 1200.
Good idea to check the parts before installation; a defective stator may sneak through QC.
I.M.B.B.A. Technician II Certified

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Tue Jul 02, 2013 8:07 pm

The person that did the work has experience with these bikes so I trust he chose the right parts

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trike lady
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Motorcycle: 1993 GL1500 Aspencade with Voyager (Sold)
1983 GL650I SilverWing Interstate

Re: Charging system still not working

Postby trike lady » Tue Jul 02, 2013 9:35 pm

Not too many shops handle Classic Wings and the CFI Wings no one wants to handle.
I.M.B.B.A. Technician II Certified

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Tue Jul 02, 2013 10:44 pm

this is where I am at. removed the new reg/rectifier and installed my old one.
tested the diodes first and all checked good on both positive and negative sides.
checked stator and had good continuity on all three phases and nothing to ground
started the bike and was charging at 13.5 at idle/13.9 at 2500 rpm
tested the stator at idle and all 3 phases were at 7 volts a/c
ran at 5000 rpm and all phases went to 14 volts a/c
after about 5 minutes of running my stator wires started to get real warm
reg/rectifier got real hot, saw the lights go dimmer and the voltage dropped from 13.9 to 12.0 then to 11.0
if let bike sit for 10 min. I can start it and it will charge again. almost like my regulator gets hot then shuts down.
don't know why the stator gets so hot. ordered the harness I have seen on this site for the charges system and I am hoping that will help.
any ideas would be great. I am considering the alternator kit and get rid of all the stock charging system.
thanks for all your input.

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virgilmobile
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Motorcycle: 1988 GL1500 I
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78 GL1000
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83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: Charging system still not working

Postby virgilmobile » Wed Jul 03, 2013 7:39 am

The stator wires get hot because of the design.
It puts out power...full bore...wide open...directly proportional to the RPM.
The rectifier/regulator module is dual function.
It changes the 3 phase AC from the stator to DC.
The regulator part of it actually shorts or shunts some of the energy of the stator to ground to keep the output from going too high.
If the regulator is bad,it will cause not only a reduced voltage but a increase in heat sink temperature and wire temperature.
As far at the temp.My 84 R/R module would run at about 165* after just 5 minutes.
It sounds like the stator is working and the R/R module is failing.
Voltage measurements on the stator while hooked up can be deceiving.
There usually measured 'open circuit'.Mine showed about 25 volts AC between any pair at 1k rpm.
When attached,I measured AC current with a clamp on meter,at 7 amp on each leg.

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virgilmobile
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Joined: Sun Sep 19, 2010 5:39 pm
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: Charging system still not working

Postby virgilmobile » Wed Jul 03, 2013 8:07 am

Here's a schematic of the system....There's not much involved...
As always,assume nothing..Be certain that there are no PO add on wiring..especially to the 3 yellow wires.They must stay isolated from the bike...
I did read about one bike where a "owner" attached a wire to the stator line and hook up lights to it....Didn't work well tho.

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Wed Jul 03, 2013 9:00 am

It's the enitial good charge at start then the no charge on each it gets warm that is confusing me. I am going to see about another new regulator. The one that got put on is only 2 hours old and the best yellow stator wires were
melted together

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virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
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: Charging system still not working

Postby virgilmobile » Wed Jul 03, 2013 9:32 am

One other point also...As I remember,your bike does have a higher demand for power...
The standard stator(charging system) is designed to produce a maximum of 360 watts at 5000 RPM.
Yours is bumped up to 475watts at 5000RPM.

This change can be measured by the AC current on the stator wires...
The "standard" will peak around 8 amp AC at 5000 rpm and yours should be around 10 amp....

As far as the charging amps....The standard should be 25 amp at 14 volts DC coming out of the 2 red wires at the regulator...Yours should be 33 amp at 14 volts.....All at 5000 RPM.

So if a standard (gl1200 interstate) regulator were used it may overheat due to the larger ammount of current it has to dissapate from the larger stator....
Just food for thought here.......The numbers i listed are just averages.

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virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
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: Charging system still not working

Postby virgilmobile » Wed Jul 03, 2013 9:35 am

petarm1 wrote: the best yellow stator wires were
melted together


Can you clarify please???A picture perhaps....Where are they melted?

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Wed Jul 03, 2013 11:12 am

I will check my amps out to nite. Just the casings were stuck together at a certain point.
I am going to see about a larger regulator

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Thu Jul 04, 2013 10:07 pm

tonite I disconnected all the accessories that the bike hade( trailer wires/ fog lamps) I also pulled all the fuses out except the ones for the bike to run. started the bike and my volts went to 15.5
I let the bike run at 2500 for about 10 minutes again and then my stator wires got real hot and then I lost my charge. dropped to 12 volts. :twisted:
this is starting to drive me crazy. is the stator to small and overheating the regulator. or is there a short in the system that is still causing me issues
I don't know. pleeeeaaaaaase help

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Thu Jul 04, 2013 10:32 pm

the other thing I just did is test the stator voltage . all three wires were at 4.7 to 5.0 volts but still get vary vary hot. to hot to touch.
I left my multi meter on tne battery and it read 12.30 volts but the dash read 11.2 volts. what do you think is up with that

mutt
Posts: 1
Joined: Sat Jul 06, 2013 9:08 pm
Location: Richmond, Virginia
Motorcycle: 1985 gl1200

Re: Charging system still not working

Postby mutt » Sat Jul 06, 2013 9:19 pm

If you havnt already come across it check over at www.gl1200goldwings.com for anything to do with the "poor boy conversion" or "Don Pigott" I did this conversion a year ago and haven't had ANY problems charging since!

Mutt

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virgilmobile
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Joined: Sun Sep 19, 2010 5:39 pm
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: Charging system still not working

Postby virgilmobile » Sun Jul 07, 2013 10:23 am

Test the stator volts on AC only with the regulator module unplugged.
It should stay cold and produce 24 vac at 1k rpm and go up much higher as the rpm is increased.
If the AC volts between 2 yellow wires to the 5-7 vac range as you attach the regulator and the wires get hot,the regulator is bad.

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petarm1
Posts: 73
Joined: Sat Sep 29, 2012 6:31 pm
Location: rycroft,alberta,canada
Motorcycle: 1985 gl1200 limited edition
1980 gl1100 interstate
1982 Aspencade gl100

Re: Charging system still not working

Postby petarm1 » Sun Jul 07, 2013 2:17 pm

I just ran the bike with the stator disconnected from the regulator and I was getting 36 vac from all three phases at 1300 rpm. when I connected my new regulator it started to smoke and the wires got hot in seconds. I am suspecting the wrong regulator is faulty and or wrong size.




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