Cover for Relays


Information and questions on GL1500 Goldwings (1988-2000)
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tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Cover for Relays

Postby tcryder » Mon Jan 25, 2016 1:23 pm



How does the relay cover come off to get at the relays. I have 94 GL1500 with Motor Trike Coupe conversion. The side covers are the same if it was still 2 wheel. I have pictures of what I mean. These are the left side cover.
Do I need to remove the bolts that hold the fuse box and relay? I have no idea how I would be able to change a relay! The fender that holds the rear of the side cover in in the way. What a pain in the ass. Not good if I am stranded. tcryder



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Mh434
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Location: Victoria, British Columbia, Canada
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1981 GL1100I
1989 Kawasaki Concours

Re: Cover for Relays

Postby Mh434 » Mon Jan 25, 2016 2:45 pm

You'll have to at least loosen the bolts for the left saddlebag to get access to the cover (I take the bolts right out, and just wiggle the bag far enough away to give me access). There's no need to remove the fuse box.

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WingAdmin
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2007 Aspen Sentry Trailer

Re: Cover for Relays

Postby WingAdmin » Mon Jan 25, 2016 3:23 pm

This is a case where the marketing/design people didn't talk to engineering when the GL1500 was on the drawing table. A total fail, in my opinion, where you have to remove (or at least loosen) a saddlebag to open the relay/fuse box (yes, there are fuses in there, too).

tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Re: Cover for Relays

Postby tcryder » Mon Jan 25, 2016 4:59 pm

This is Motor Trike conversion on my 94 GL 1500A so I have no saddlebags. I remove the side cover from the left side, I can get the fuse cover off but not the one that has the relays.
As you can see in this photo, the relay cover is behind the side cover mounting holes which is a molded fender on the conversion. tcryder

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Mh434
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Location: Victoria, British Columbia, Canada
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Previous:
1981 GL1100I
1989 Kawasaki Concours

Re: Cover for Relays

Postby Mh434 » Mon Jan 25, 2016 10:15 pm

Okay, I'd missed the part about the trike conversion, sorry. That does make it tougher - I don't know what to suggest, unless there's a provision for undoing the bolts on the front of the bodywork & tilting it back?

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PedroTQ
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Location: Perth, Western Australia
Motorcycle: Motorcycles on the road;
1988 GL-1500

Re: Cover for Relays

Postby PedroTQ » Tue Jan 26, 2016 3:53 am

G'day from the Oz,

Yeah that really looks like a bad thought from Mother Honda.

I discovered on my 88 that if you remove the two bolts holding the complete relay block in position (one bolt at top and the other at bottom).

Then with the correct tongue twisting and a little flexing of the saddlebag ears that hold the sidecover the relay box just squeezes out, then cut the cable-tie that holds the harness to the right side of the relay box, then all can be accessed. But it is a tight squeeze, and I have not re-cable-tied the harness down for ease next time.

I hope this helps ;)

Peter.
#1 - 1975 GL-1000 - showroom
#2 - 1976 GL-1000 - sidecar
#3 - 1978 GL-1000 - parts
#4 - 1975 GL-1000 - parts, but had the sidecar
#5 - 1978 GL-1000 - project with grandson (secret parts source)
#6 - 1988 GL-1500 - Flagship!
#7 - 1998 GL-1500C - Valkyrie

tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Re: Cover for Relays

Postby tcryder » Tue Jan 26, 2016 7:27 am

I just wanted to be prepared for the road trip we are taking this summer. I just hope we never have to change a relay. I bought two spare relays in case they fail. They will not do any good if I cannot remove cover. tcryder

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WingAdmin
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2007 Aspen Sentry Trailer

Re: Cover for Relays

Postby WingAdmin » Tue Jan 26, 2016 11:21 am

You might want to contact the trike manufacturer and see what they suggest. They may have already thought of (and designed in) a procedure to access that relay box.

tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Re: Cover for Relays

Postby tcryder » Tue Jan 26, 2016 1:38 pm

My plan is to modify/cut body where the side mounting holes are. I would cut just above lower mounting hole leaving the bottom one in place.
See the white line I drew is the cut line. My spare relays are no good if I can't change them. Thanks for all your input. tcryder.

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MikeB
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Motorcycle: 1998 - GL1500 Aspencade.
2003 - GL1800A

Re: Cover for Relays

Postby MikeB » Tue Jan 26, 2016 2:20 pm

Like WingAdmin stated, call Motor Trike before you do any cutting. I am sure they have had more than a few inquires about this. If you cut it first, you may be very unhappy to find that there is a better way,
MikeB
Tacoma, WA, USA

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baba67
Posts: 55
Joined: Sun Jul 26, 2009 8:16 am
Location: Cape Cod, MA.
Motorcycle: 1986 GL1200 Aspencade
1997 GL1500 SE W/ Voyager trike kit

Re: Cover for Relays

Postby baba67 » Tue Jan 26, 2016 3:17 pm

Hi
I just wanted to say that Pedro is correct.
You can remove the entire relay panel by removing the two 10mm bolts that hold it in place.
It requires a little finness to squeeze it by and through the opening, but it does come out and go back in without any damage.
I have had mine out two times now, and will be removing it again to modify the low beam headlight relay socket to accept a timer delay relay for my HID headlights.
It allows a 10 second delay before the HID lamps come on.
I will let you know how that works out.

tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Re: Cover for Relays

Postby tcryder » Tue Jan 26, 2016 7:57 pm

Is there enough wire to allow the fuse/relay box outside of the bike frame? tcryder

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baba67
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Location: Cape Cod, MA.
Motorcycle: 1986 GL1200 Aspencade
1997 GL1500 SE W/ Voyager trike kit

Re: Cover for Relays

Postby baba67 » Mon Feb 01, 2016 12:36 pm

Yes there is enough wiring in the harness to come well beyond the frame. (at least on my bikes)
And I noticed that if you remove the cover and pull a couple of relays it slips right out with no effort at all.
I generally leave the cover on and just manipulate it thru the opening.
To be SAFE... Always Disconnect your battery ground cable before working on electrical parts..

tcryder
Posts: 47
Joined: Fri Nov 27, 2015 8:19 am
Location: Park Rapids MN
Motorcycle: 1994 GL1500A Aspencade with 2006 Motor Trike conversion.

Re: Cover for Relays

Postby tcryder » Mon Feb 01, 2016 5:01 pm

Thanks for the information, don't need to get at the relay box yet. Just wanted to know how to get out if needed while on the road. I bought a couple extra relays and carry along. tcryder.

Jerryv693
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Joined: Mon May 21, 2012 9:06 am
Location: Virginia, Minnesota
Motorcycle: 1993 GL1500SE with MotorTrike Coupe kit

Re: Cover for Relays

Postby Jerryv693 » Thu Apr 14, 2016 4:13 pm

I have the exact problem that tcryder referred to and had a bad relay for low beam headlights. I called MotorTrike and spoke with a tech there. These were his instructions and I succeeded in replacing my bad relay. You have to remove the upper and lower 10mm bolts that hold the assembly to the frame. From this point you fuss with the unit working it back and down and soon you will have just enough room to remove the cover. Hope this helps anyone else facing this.




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