1984 GL1200A ELECTRICAL PROBLEMS


Information and questions on GL1200 Goldwings (1984-1987)
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mlampada
Posts: 5
Joined: Mon Aug 17, 2009 3:00 am
Location: GOSFORD, NSW
Motorcycle: 1984 GL1200A ASPENCADE

1984 GL1200A ELECTRICAL PROBLEMS

Postby mlampada » Sat Aug 29, 2009 1:38 am



Greetings from Australia,

I recently bought a 1984 ASPENCADE in great condition with only 31,000 miles on the clock.
It was going great till the Stator packed it in. So I renewed the Stator and Regulator.
Now after 4 months it stopped charging again.
Am thinking of fitting a car Alternator to it as I do not like the idea of taking out the engine again.
Has anyone had this sort of problems with the charging system failling twice.
Would appreciate any recommendations or suggestions. As i am new to the Wings.

Regards
Bro Michael



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WingAdmin
Site Admin
Posts: 17050
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: 1984 GL1200A ELECTRICAL PROBLEMS

Postby WingAdmin » Sat Aug 29, 2009 8:08 am

The stator in the 1200 is a known weak spot. You can try the "Poorboy" alternator conversion - you can see instructions and pictures for it on the Poorboy Conversion web site.

If you go with the poorboy kit, here are the belt numbers you will need:

Gates K030290

Dayco 5030290

Goodyear 4030290

Driving Force 290K3

BladeRunner9
Posts: 59
Joined: Sat Jul 18, 2009 10:44 am
Location: Ontario Canada
Motorcycle: 1987 GL1200 Aspencade
1984 GL1200 Standard
1988 GL1500

Re: 1984 GL1200A ELECTRICAL PROBLEMS

Postby BladeRunner9 » Sat Aug 29, 2009 10:29 pm

OK, I've read many posts with great interest all about the stator "problem"; I just recently got an '87 Aspencade, everything seems to work well. I have nearly completely torn it down to give it a long overdue cleaning, change all the fluids, timing belts, brake fluids etc. I looked for some indication that my stator was good, bad or otherwise;
I didn't see a problem...until I pulled apart the connector at the rectifier...two of the pins or rather the plastic plug connections are just starting to melt! A closer inspection of the stator 3 pin plug tells me it IS starting to be a problem, so far the plug looks fine...BUT....I can't unplug it! Must be melted a bit inside.
So; if I have this right; It's acually NOT the stator itself,but, rather the undersize wiring that heats up to the point that the weakest link ( stator plug ) melts allowing the wires to touch and THEN the stator shorts out??
Of coarse those that have added "extras" like the unsual Goldwing lights etc.....only have this happen all that much sooner??
That's the conclusion that I have reached, in no way am I an expert,but, it seems pretty straight forward from all that I have read.
Lucky for me..we have forums like this one to help with all the unknown and common issues that otherwise we wouldn't have access to..Thanks goldwingdocs.com!! :D

mlampada
Posts: 5
Joined: Mon Aug 17, 2009 3:00 am
Location: GOSFORD, NSW
Motorcycle: 1984 GL1200A ASPENCADE

Re: 1984 GL1200A ELECTRICAL PROBLEMS

Postby mlampada » Sat Aug 29, 2009 11:08 pm

Thanks to all that have replied to my problem.

I have done a trace on the fualt. renewing again the regulator.
Checked out the Stator not short found. But one of the Yellow wires is not giving correct Ac volt reading compare to the other two.
The Bike runs great during the Day but as soon as you turn on the lights the charging system fails to charge giving only 11.35 DC Volts at the Battery, which is not enough to recharge the Battery.
Have checked out the Conversion to an external Alternator.
Found one small enought to fit in the bike. now have to work out how to run it. Either from the Crankshaft or possibly off the Cam (going this way will eliminate doing any modyfications to the Radiator).

Again Thanks will keep all informed on the progress.

Bro Michael

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WingAdmin
Site Admin
Posts: 17050
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: 1984 GL1200A ELECTRICAL PROBLEMS

Postby WingAdmin » Sat Aug 29, 2009 11:45 pm

BladeRunner9 wrote: I didn't see a problem...until I pulled apart the connector at the rectifier...two of the pins or rather the plastic plug connections are just starting to melt! A closer inspection of the stator 3 pin plug tells me it IS starting to be a problem, so far the plug looks fine...BUT....I can't unplug it! Must be melted a bit inside.
So; if I have this right; It's acually NOT the stator itself,but, rather the undersize wiring that heats up to the point that the weakest link ( stator plug ) melts allowing the wires to touch and THEN the stator shorts out??
Of coarse those that have added "extras" like the unsual Goldwing lights etc.....only have this happen all that much sooner??


It's a possibility - have a look at the pictures of my melted stator plug - you'll notice it's the resistance of dirty connectors that causes the heat and eventual failure. If you cut the connector out entirely and solder the wires directly, you'll have no problem.

The stator won't be damaged by shorting the wires out - that's in effect what the regulator does with the excess power anyway. The stator always puts out full power, and the regulator shunts to ground the power it doesn't require to run the bike and charge the battery.

BladeRunner9
Posts: 59
Joined: Sat Jul 18, 2009 10:44 am
Location: Ontario Canada
Motorcycle: 1987 GL1200 Aspencade
1984 GL1200 Standard
1988 GL1500

Re: 1984 GL1200A ELECTRICAL PROBLEMS

Postby BladeRunner9 » Sun Aug 30, 2009 12:05 am

Thanks for the reply WingAdmin; I plan to do just that, I WAS going to get that kit that electrical connection has.( see my other post ); I really like the idea of running the coils directly from the battery..makes a lot of sense, one more load eliminated from the wiring circuit... :D

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tricky
Posts: 341
Joined: Fri Jun 26, 2009 4:14 pm
Location: Canada

Re: 1984 GL1200A ELECTRICAL PROBLEMS

Postby tricky » Sun Aug 30, 2009 11:03 am

I had two alternators go, but both performed for about 70,000k each.
I changed to the external before the third one went, the bike has +220,000k
I would seriously reconcider your idea of running the external from the cam, your putting a greater strain on one of the belts for one thing.
Running of the crank is a much simpler method and any changes to the radiator fan are minor. depending on what size drive pulley you go to, the bigger the pulley the further out the rad has to be at the bottom. Using a 1-1 ratio will give you the same output that the present stator does but the external is capable producing much more using a 2-1 will provide +12 at idle even with additional lighting on.




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