86 gl1200 SEi wiring nightmare


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roadwanderer2
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86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Thu Jun 02, 2016 6:49 am



hey guys, here's a new question for ya's. is there a neutral safety switch on the GL1200's and if so, where is it located. is it in the same place as the ones on the 1100's? buried deep down under the air breather box? or is it in a more "convenient" place where i can get to it without pulling most of the top of the bike apart lol.

the only reason im asking is somehow my bike's electrical system got all screwed up yesterday. my starter wont spin and the 4 wire plug that goes to the starter solenoid, when i went to change the solenoid yesterday thinking i might have a bad solenoid, 3 of the main wires were so brittle they broke off the 4 plug connector and since someone has installed 3 inline fuses together,(solid red wire and a red/white striped wire from the main wiring harness), and wire-tied them into the connector, now that they are all broken off the 4 prong solenoid plug, i have no idea which wire goes where :twisted:. i can't get any power to the bike unless i take one of the wires and ground it to the 2 main battery prongs on the solenoid which when i do that, the solenoid gets VERY hot almost to the point that it can't be touched with my hand.

when i try to start it up, i pull the clutch lever in, all the lights go off and i get nothing not even a click from the solenoid. i dont know what possessed someone to hard wire in 3 inline fuses to the solenoid, but someone did, and now i cant figure it out as there are too many wires going to the solenoid. i need to disable the neutral safety switch so i can try to figure out what wires belong where and i can't hold any wires while trying to start the bike up because of the neutral safety switch.

stuart.


Last edited by roadwanderer2 on Thu Jun 02, 2016 7:05 am, edited 1 time in total.

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virgilmobile
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Re: neutral safety switch

Postby virgilmobile » Thu Jun 02, 2016 7:01 am

First..remove the seat. :lol:
Actually its attached to the inside of the front cover.To the right side of the water pump area.
You do have to drain the oil and antifreeze.

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roadwanderer2
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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Thu Jun 02, 2016 7:08 am

what :o, you mean i have to take the front engine cover off the motor? there's no way im doing that. is there another way to bypass it without ripping the motor apart?

if you read my entire posting, you'll understand why i need to disable it. i know where the one is thats on my 1100, i already disabled that one with a jumper wire, but i cant find the one on my 1200. is this one in the same place as the ones on the 1100's?

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby virgilmobile » Thu Jun 02, 2016 9:14 am

Stuart.
Do you have a DVM. Or volt/ohm meter.
I can help sort out the wiring problem enough to get it running.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Thu Jun 02, 2016 9:51 am

now see, thats just one part of the problem. right now, its not going to crank because my starter isn't turning. last time i tried starting it the starter started to drag so bad it ran my battery down, and just before the plug wires broke out of the 4 prong solenoid plug, it killed the starter, so even if i had the wires correct, it still won't crank over until i replace the starter, again :cry:. for now i just need to get the wires on their correct solenoid pins.

i know someone in my area that had one of these SEi's, and he's a bike tech, so im gonna give him a call and ask him if he can come over and help me with the wiring.

the starter is under a 1 year warranty, so im gonna pull it out and send it back to the company for a replacement starter.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby virgilmobile » Thu Jun 02, 2016 10:50 am

I see, more than one problem to solve.
This schematic might help.

The yellow/red should have volts when you push the start button with the key on.
The green/red...if you use a test light attached to this wire and the positive post of the battery,it should light when in neutral or when the clutch handle is pulled in.
The 2 big red ones CAN be removed from the starter solenoid..bonded together and 30 amp fused direct to the battery post or cable.
That leaves only the 2 small wires needed to make it click. Two of the four terminals on the solenoid are bonded/tied together.If you cannot see it, use your meter to measure resistance for a dead short/zero ohms...Do not attach the small wires there.The other pair make it click.I think the coil terminals measure a few hundred ohms.Not positive but certainly not a short.

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Thu Jun 02, 2016 11:00 am

Stuart - Wiring for your bike should be identical to my LTD.

The red wire is to the ignition switch. The red/white striped wire is from the stator and charges the battery. These two wires are connected somewhere upstream (know this because with the red/white striped wire disconnected from the RR and the starter solenoid the red/white striped wire is still hot). These wires are connected to the live terminals of the starter solenoid.

The yellow/red striped wire comes from the starter/engine stop switch to energize the coil internal to the starter solenoid, and to provide power to the Green/red striped wire. Connect these wires to the "dead" connectors.



Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Thu Jun 02, 2016 11:27 am

Stuart - you have mentioned that you have had the bike out and about. My LTD does not require the clutch be pulled in to start if in neutral, only when in gear.

From the starter solenoid there should be one red wire with a 30 amp in-line fuse off the battery connection going up and under the seat. This wire connects to a small connector just under the seat. It powers a main relay for the system. This wire should be the only additional wire from the starter solenoid.

Pictures of the wire I talk about. First is connection under seat:

Here is wire connected at starter solenoid:


Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Thu Jun 02, 2016 1:32 pm

hey rednaxs. thanks for the diagrams, i printed them out and im going to keep them right next to me once i start trying to find these wires that are under the seat and frame. the only problem with the wires are that they are so short its hard to find them between the frame and the battery box, but i'll keep looking for them.

once i get a hold of my friend, i'll have him look for the wires and together we should be able to sort this mess out.

thanks again,

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Thu Jun 02, 2016 5:47 pm

Not a lot of room to work with!!
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Thu Jun 02, 2016 7:55 pm

your telling me. i can barely get 3 fingers in there to grab any of the wires. what i might do is before getting all these wires corrected, solder and heat shrink some longer wires to make it easier to get at. what gauge wire would you recommend i use, 14 or 16 gauge.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Sat Jun 04, 2016 8:57 am

'mornin everyone.

ok, since my "friend" didnt show up yesterday, i took the diagram outside and tried to find the wires that are going to the s/s switch and heres what i found...............

there are 6 wires coming off the main harness and are as follows.........

1 large red wire with an inline fuse,
2 wires- 1 solid red and a red with a white stripe tapped together with an inline fuse,
green/red striped wire
2 y/r striped wires taped together.

i tried to put the wires on according to what the diagram that rednaxss posted, but its not working. i had the lights working once, but i think all the stress that was on the starter also discharged my battery so im taking the battery back to the parts store to have it tested and charged up.

below are 2 photos of the wires that we are trying to figure out to the solenoid.

stuart.
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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Sat Jun 04, 2016 1:05 pm

ok, after trying every combination of solenoid wire connections with the main wires, the starter still wont spin. even when i "jumped" the top 2 battery terminal wires on the switch, i get nothing, no clicks no cranking.......nothing. im gonna take the starter out and "bench test" it. if its not working, its going back to the manufacture on Monday for a replacement starter.

right now im glad i haven't sold my 1100. at least i still have something to ride while my 1200 is down.

stuart.

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Re: neutral safety switch

Postby roadwanderer2 » Sat Jun 04, 2016 1:14 pm

virgilmobile wrote:First..remove the seat. :lol:
Actually its attached to the inside of the front cover.To the right side of the water pump area.
You do have to drain the oil and antifreeze.


maybe i should have rephrased this question.....where is the neutral safety switch diode located. i know where the one on my 1100 is, but i cant find the one thats on my 1200 IF it has one.

stuart.

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Rednaxs60
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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Sat Jun 04, 2016 7:37 pm

roadwanderer2 wrote:'mornin everyone.

ok, since my "friend" didnt show up yesterday, i took the diagram outside and tried to find the wires that are going to the s/s switch and heres what i found...............

there are 6 wires coming off the main harness and are as follows.........

1 large red wire with an inline fuse,
2 wires- 1 solid red and a red with a white stripe tapped together with an inline fuse,
green/red striped wire
2 y/r striped wires taped together.

i tried to put the wires on according to what the diagram that rednaxss posted, but its not working. i had the lights working once, but i think all the stress that was on the starter also discharged my battery so im taking the battery back to the parts store to have it tested and charged up.

below are 2 photos of the wires that we are trying to figure out to the solenoid.

stuart.


Stuart - the red wire with the in line fuse should go from the battery terminal of the starter solenoid and up under the seat to the single white connector under the seat.

The other solid red should go to the ignition switch and is live at all times. There is a fuse on it (forgot I replaced the solenoid with a solenoid that has a blade type fuse integral to the unit).
The red-white striped wire is from the RR and is live at all times.
The grn-red striped wire and the yellow-red striped wires come from the fuse block and go out to the system respectively. There should only be one yellow-red striped wire at the starter solenoid.

Identify the red wire that goes to the white connector under the seat first. Connect it to the battery terminal of the starter solenoid. After you do this, connect the other wires as per my drawing. There should only be one yellow-red striped wire - you will have to follow it and see where it goes, or comes from.

After you do this, you should have power as is required.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Sun Jun 05, 2016 8:49 am

hey rednaxs, i've tried to trace some of those wires, but they are tied into the main wiring harness just to the inside of the frame and its impossible to get to all of them. i would have to strip away all the tape thats holding all of them to the loom to trace them. right now, with all the wires that are there i cant get to them.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Sun Jun 05, 2016 10:18 am

Stuart - do you have the electrical supplement for your bike. I'm thinking it is the same as for my LTD. I have an electronic copy and can send. It shows how the hook up is and where the wires go. Would need your email.

Can you find the single white connector just under the seat as per the picture I posted? It is right where everything joins. That wire is not in the main harness from what I have seen and is one of the red wires at the starter solenoid (the rats nest you show). I'm also thinking it is the extra red wire that is separate from the red and red/white wire that is joined together. The red and red/white wire that are joined - the red is for the ignition and the red/white is from the RR for charging.

The other wires should all be in a single harness going from the starter solenoid and disappearing into the main wire harness.

Here is another way to hook up the wires. The red and red-white striped wires are all live and can be hooked up to the battery connection on the starter solenoid. Join them all together with a Marrett (those electrical house wire connectors) temporarily and run one wire to the battery connector. The other two wires hook up as per the drawing. Let me know.

I know about getting into the wire harness. Just stripped out the yellow stator wires, the red/white wire from the RR and disconnected the wire splice where the red and red/white wire are spliced in the centre of the harness. There are a lot of wires in there.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Sun Jun 05, 2016 3:12 pm

ok, i sent you a PM.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Mon Jun 06, 2016 8:30 am

well, i did some searching for the correct wiring diagram for my 86, and i found it. believe it or not it was right on this site in with the GL1200 manuals, so i downloaded it and it IS "bike specific" to the 1986 GL1200 SEi :D.

now rednaxs, it does show the white wire on the page and in your description, but i cant find it on my bike's wires. if it is there, its definitely buried deep within the harness. the only wire that has an inline fuse is a red wire that also has the r/w striped wire attached to it.

i can't do much work on it today because i have an Dr's appointment at the VA hospital in murfreesboro Tn, and im gonna take my other bike. its a 185 mile 2 1/2 hour ride so i wont be back until later approx. 3-4 pm.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Mon Jun 06, 2016 11:02 am

Hear you on the wiring. Honda did a small slight of hand regarding the white wire from the starter solenoid as shown o the schematic. It is a plain red wire from the starter solenoid to the in line fuse. After the in line fuse it transitions to a white wire that goes to the single connector under the seat as I show in my picture.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Mon Jun 06, 2016 5:39 pm

i'll take a look for it later, i just got home and im taken the wife out to dinner. im starving, i haven't had anything to eat yet today so my calorie count is very low for today. im on a restricted diet. im only allowed 1,500 calories a day so i can loose some weight. all i've had to day was my morning coffee which is only @ 8 calories for the coffee and @ 10 calories for the creamer =18 claories, so i need to get something to eat. i'll recheck the wiring when i get back from dinner.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Tue Jun 07, 2016 1:55 pm

ok, after spending 2 1/2 hours on the phone this morning, (mostly on hold), i finally got thru to a company rep from the company i bought my starter from and got an authorization to get a replacement starter for my bike, so right now im dead in the water without the starter, so that leaves me "free time" to fix the wife's car tomorrow morning. the plastic outside door handle broke off of driver's door and i have to replace it, which means i have to push my bike out of the garage so i can fit her car inside so i can be closer to my electric power and tools and pull the whole inside door apart so i can get to door handle bolts from the inside of the door. lucky me :cry: lol. after thats fixed i can start to remove the starter from the bike and ship it to the company and wait for another one to arrive here in the next 7-14 days. :evil: oh joy.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Wed Jun 15, 2016 10:22 am

okie dokie, i got the new starter on the bike this morning and im still trying to figure out the wiring on this solenoid. even with the diagrams and book specs, im still having a problem with it, but im persistent, i'll get it.........eventually lol. i did manage to get the bike to crank over,(but not start up), only if i held one of the hot wires to one of the other hot wires, but it got the wires so hot, i couldn't touch them after a couple of seconds. i dont want to fry the bike's electrical system.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby roadwanderer2 » Sat Jun 18, 2016 10:35 am

on my "last ditch" effort to get these wires correct on my own without having to call someone over to fix it for me, i tried yet again to get these solenoid wires in their correct order so i can get my bike fired up. glad i had a spare starter solenoid to use because the one that was on it i fried trying to get everything corrected, i FINALLY FINALLY got it right. after i connected the last wire, i got all my dash lights, pressed the starter button and the bike fired right up like it normally does. NOW i can finish buttoning everything up that i had to remove to replace the starter.

thanks goes out to everyone that helped me on this. rednaxs, thank you very much for the detailed diagram for the solenoid switch wires. without you i couldn't have fixed this. now i can put Thelma back into the garage and take Louise out for a nice LONG ride today.

i found one of these............http://www.ebay.com/itm/Starter-Relay-S ... ki&vxp=mtr on ebay and i purchased it because the one that was on my bike's wiring was burnt to a crisp and i had no color coded wires to follow, thats what was giving me so much trouble. now when my new one arrives, i can wire it directly to the solenoid wires and have a nice new connector plug to plug in.

stuart.

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Re: 86 gl1200 SEi wiring nightmare

Postby Rednaxs60 » Sat Jun 18, 2016 1:51 pm

Glad you got the wiring sorted out and the bike is running.

Nice find on the connector. Too bad no shipping to Canada.

Cheers


"When you write the story of your life, don't let anyone else hold the pen"

Ernest


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