anybody know what this part is/does?


Information and questions on GL1200 Goldwings (1984-1987)
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Big-Bob
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anybody know what this part is/does?

Postby Big-Bob » Wed Aug 17, 2011 8:18 pm



I am having problems with the charging system on my LTD, and I found a part which I believe may be a part of the charging system, but cannot find any reference to it in the manuals. It is a black box, rubber mounted to the same bracket as the PLR/PBL sensors. It has 3 wires coming out of it, black, green, and red/white, and going to a white plastic connector to the lower left. Anybody know what this part is, and what it does?



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virgilmobile
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Re: anybody know what this part is/does?

Postby virgilmobile » Thu Aug 18, 2011 8:49 am

This is what I see on the schematic.Not related to the charging system.What are your symptoms?
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Re: anybody know what this part is/does?

Postby virgilmobile » Thu Aug 18, 2011 8:52 am

This schematic is the charging system.
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Big-Bob
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Re: anybody know what this part is/does?

Postby Big-Bob » Thu Aug 18, 2011 10:21 am

Thank you very much. It was suggested to me by a member of another forum that this might have something to do with the charging system because of the colors of the wires. I spent over an hour last night (admittedly in dim light) going over schematics trying to find it.

Symptom is SEVERE overheating of the R/R. All three plugs (the one by the battery, and the 2 at the R/R) have already been removed and the wires properly soldered together. It still gets super hot, hot enough to burn you in just a second, and hot enough to burn through the insulation on a wire that was touching one of the fins. System charges fine, I'm getting 13.7V-13.9V at the battery terminals. Bob.

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Re: anybody know what this part is/does?

Postby Pam » Thu Aug 18, 2011 1:45 pm

Is it possibly the voltage regulator>>>>?????????

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virgilmobile
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Re: anybody know what this part is/does?

Postby virgilmobile » Thu Aug 18, 2011 2:03 pm

Very hot to the touch is normal,melting wires is not.
The R/R module contains a block of diodes and other parts.It's purpose in life is to short to ground any excess current that's not needed by the bike.

With that in mind,2 possibilities present themselves.Either the R/R module is partially shorted or the bike is not drawing enough power from it and it's having to dissipate more than it should.

Scrutinize the battery condition and connections including the ground lug and the dog bone fuse.If all that's OK then replace the module.

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virgilmobile
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Re: anybody know what this part is/does?

Postby virgilmobile » Thu Aug 18, 2011 2:45 pm

Here's the basic test of the regulator.There are 6 diodes to be tested with a meter.
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Big-Bob
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Re: anybody know what this part is/does?

Postby Big-Bob » Thu Aug 18, 2011 3:14 pm

Thanks for all the replies. The part in question is indeed the fuel pump shut off sensor, so it has nothing to do with the charging system. I tested the R/R according to the procedure in the Clymer manual, and it showed ok. The dogbone fuse has already been replaced with a heavy duty automotive fuse holder and 30 amp blade type fuse. Battery connections are fine, battery tests ok, and is only 3 months old. R/R is properly grounded. I'm beginning to wonder if the problem might be the R/R even though it tests ok. It is ONLY the R/R that gets super hot. Even though the wires going to/from it go through a rubber block, it has gotten hot enough to damage the wire 2-3 inches away. The insulation on all the wires is discolored, and the insulation is very hard when cold. A few inches farther away, and the wires are fine. Bob

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virgilmobile
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Re: anybody know what this part is/does?

Postby virgilmobile » Thu Aug 18, 2011 4:26 pm

Do you have the equipment to check the charge going to the battery? and measure the 3 phases of the stator current ?
When I tested my 84,I found right after starting (holding 3000 rpm)the battery would draw 14 amp from the system and dropped to 3.5 amp after 4 minutes(Battery charged).This left the remainder to run the bike (10.5 amp draw).So doing a bit of math,,10.5 amp x 13.5 volts=142 watt...3.5 amp x 13.5 volt=47 watt..added together =189 watt.the system is maxed at 300 watt so there should be ABOUT 111 watt needed to be dissipated in the regulator circuit.Not terribly hot.

If your voltage is a bit low,eg 13.3 @ 3500rpm,it's being sucked off somewhere.By what you describe,it's the regulator.
Being a full bore ,wide open charger,the yellow wires should have a max of 300 watt output.3 wires divided by 300 watt is 100 watt per leg or near 7 amp at 3500 rpm.




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