GL1200 with small fire. HELP!


Information and questions on GL1200 Goldwings (1984-1987)
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mac159218
Posts: 6
Joined: Mon May 30, 2011 11:04 am
Location: Pensacola, fl
Motorcycle: 1986 GL1200 Aspencade

GL1200 with small fire. HELP!

Postby mac159218 » Mon May 30, 2011 8:58 pm



Hi folks, I'm new to this site so please bear with me. I have a 1986 GL1200 Aspencade that I love a lot. My son borrowed the bike to take a longer ride than he wanted to try on his Suzuki M109R (seat like a rock). Anyway, he stopped for gas and had to jump start the bike, it ran fine then. Guages all looked good etc. Just as he was getting back on the Interstate he says he could smell rubber burning. Whipped the bike to the side of the road and had smoke coming out from behind the battery cover. Snatched that off and had a lovely little fire going at the connector (stator/regulator) the side of the battery melted off, but he got the fire out.

All that to say this. How can I figure out what went wrong? What procedure do I need to go through to test the stator and regulator, battery is a non-item at this point. Be kind folks, remember I really like the bike and really would like to get it running again, but not if it is going to cost more to fix it than it would to part it out and get a different bike. :| Thanks in advance. I am sure glad I found this site today. Mac



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trike lady
Posts: 872
Joined: Thu Mar 24, 2011 5:58 pm
Location: Butler, PA
Motorcycle: 1993 GL1500 Aspencade with Voyager (Sold)
1983 GL650I SilverWing Interstate

Re: GL1200 with small fire. HELP!

Postby trike lady » Mon May 30, 2011 11:29 pm

It sounds like the white 3 place connector that has the three yellow stator wires got roasted.
Test the stator and the regulator.
What happens is over time the connector experiences corrosion on the pins and socket and it generates heat and then melted plastic connector or burns as yours did.
Take the six yellow wires and solder them together ( In pairs) and double shrink wrap them individually.
Stator leads test: AC1 to AC2, AC1 to AC3, AC2 to AC3 and then the AC leads to ground. Use Ohms setting
Regulator Diode test: Both Forward and reverse bias. Change leads diodes should only feed one way set meter to 'Diode' setting
BCL to AC1, BCL to AC2, BCL to AC3. G to AC1, G to AC2, G to AC3.
Switch test meter leads and repeat above.
I.M.B.B.A. Technician II Certified

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thrasherg
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Joined: Tue Oct 20, 2009 11:21 am
Location: Plano, TX
Motorcycle: 2004 GL1800, 2005 Honda Shadow 750, 2008 Yamaha R6 with RG500 engine, CRF450X, CRF230, CRF250X, XR200, CR500

Re: GL1200 with small fire. HELP!

Postby thrasherg » Tue May 31, 2011 9:31 am

I would second Trike Lady's diagnosis.. I suspect the 3 pin connector was corroded and just got so hot that it melted the plug and started the fire. We do advise everyone to remove the 3 pin plug and join the wires permanently with a good soldered and insulated joint. I would be looking to replace the damaged wires and battery and then start it up and just check that the alternator is working correctly. Measure the volts on the battery with the ignition turned on but the engine not running, then start the engine and measure the volts again.. The reading should be higher with the engine running than the first measurement. If you hold the engine revs at around 1500RPM you should see between 13.8 and 14.4 volts if everything is good. I would also check the connectivity between the 3 wires coming from the alternator and ground to make sure the fire didn't damage any electrical insulation and cause a short circuit.

Gary

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WingAdmin
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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: GL1200 with small fire. HELP!

Postby WingAdmin » Tue May 31, 2011 1:23 pm

Likely that three-pin connector melted and failed and stopped charging the battery, which is why he had to jump start it in the first place. If he had tried to determine at that point why the battery wasn't charging, he might have found that melted connector. Unfortunately he continued on, and the connector continued to get hotter until it ignited. The advice above is correct, hopefully your stator has not been damaged.

mac159218
Posts: 6
Joined: Mon May 30, 2011 11:04 am
Location: Pensacola, fl
Motorcycle: 1986 GL1200 Aspencade

Re: GL1200 with small fire. HELP!

Postby mac159218 » Wed Jun 01, 2011 9:35 am

Thanks a whole bunch. I'll do the testing thing as soon as I get home tonight. Good info, great site. Mac

SAILOR
Posts: 117
Joined: Sat Jan 01, 2011 11:24 am
Location: lakewood,wa
Motorcycle: 1984 honda goldwing

Re: GL1200 with small fire. HELP!

Postby SAILOR » Fri Jun 03, 2011 10:01 pm

Is there a how to article some where that shows in detail how to soider those stator wire?

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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: GL1200 with small fire. HELP!

Postby WingAdmin » Sat Jun 04, 2011 11:17 am

I never did one - it's fairly simple. Find the plug next to the solenoid that has three yellow wires on each side. Disconnect the plug, and clip the plugs off. Solder each one of the yellow wires to one of the other yellow wires (doesn't matter which connects to which, as long as one from the top is connected to one from the bottom), and insulate them well - I prefer shrink tubing for these. That's all there is to it!




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