Burnt wires


Information and questions on GL1100 Goldwings (1980-1983)
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Sipho
Posts: 5
Joined: Sun Apr 25, 2021 6:44 am
Location: South Africa
Motorcycle: GL1100 '81

Burnt wires

Post by Sipho »



Hello. The wires on my old 1100 burns between the alternator and the regulator/rectifier.

I've been in an accident quite a few years ago and some buddies got it running again. I think they had some wannabe mechanics working on it, because even me as officially technically retarded can see that they did some weird things.

The wires burnt inside a little connecting plug on the negative side of the battery where the 1000's rectifier used to sit (if I understand the diagrams an sheet correctly). I bypassed the plug, it started, charged, and burned again in roundabout a minute. Now what? Must it go through the plug? Is the rec/reg gefok? I have no idea.


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DenverWinger
Posts: 1939
Joined: Thu Jun 23, 2011 2:20 pm
Location: Denver, CO
Motorcycle: (s)
1980 GL1100 STD Vetter (2005-)
1993 GL1500 Aspencade (2017-)
1983 Trav-Lite Camper (2010-)
Past rides
1972 CL350 (1980-1988) sold
1978 Suzuki GS550 (1985-2005) sold
1977 GL1000 (2002-2006) sold

Re: Burnt wires

Post by DenverWinger »

Most people just solder the wires from the stator to the wires going to the rec/reg. There's a lot of current going thru them and that will cook your average connector.

If your charging voltage is good after soldering the wires your rec/reg is probably OK. You should see around 14.5 volts at the battery at 3000 RPM.

If not, there's a way to test the rectifier diodes with an ohm meter.
♫ 99 Little Bugs in the Code, ♪
♪ 99 Bugs in the Code. ♫ :(
♫ Take one down, Patch it around, ♪
♫ 127 Little Bugs in the Code. ♫ ♪ :shock:

~Mark
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Sipho
Posts: 5
Joined: Sun Apr 25, 2021 6:44 am
Location: South Africa
Motorcycle: GL1100 '81

Re: Burnt wires

Post by Sipho »

"There's a lot of current going thru them and that will cook your average connector."

Thank you. That could be it. But why does it burn right there. There's quite a few inches of other places to burn. When bypassing it I didn't use connectors because I didn't have any. Just the old "winding up an insulation tape" stuff.
User avatar
DenverWinger
Posts: 1939
Joined: Thu Jun 23, 2011 2:20 pm
Location: Denver, CO
Motorcycle: (s)
1980 GL1100 STD Vetter (2005-)
1993 GL1500 Aspencade (2017-)
1983 Trav-Lite Camper (2010-)
Past rides
1972 CL350 (1980-1988) sold
1978 Suzuki GS550 (1985-2005) sold
1977 GL1000 (2002-2006) sold

Re: Burnt wires

Post by DenverWinger »

Burns right there because your connection wasn't good enough to pass all the current needed and caused resistance which caused heat.

Also possible a shorted diode in the rectifier, so check your charging voltage right away after repairing the wires lest you damage the stator.
♫ 99 Little Bugs in the Code, ♪
♪ 99 Bugs in the Code. ♫ :(
♫ Take one down, Patch it around, ♪
♫ 127 Little Bugs in the Code. ♫ ♪ :shock:

~Mark
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Sipho
Posts: 5
Joined: Sun Apr 25, 2021 6:44 am
Location: South Africa
Motorcycle: GL1100 '81

Re: Burnt wires

Post by Sipho »

Thank you. I'll take it from there. Make some proper heavy duty (for lack of a better term) connections, see what happens and take it from there.
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WingAdmin
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Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (sold)
1998 XV250 Virago (sold)
2012 Suzuki Burgman 400 (wife's!)
2007 Aspen Sentry Trailer

Re: Burnt wires

Post by WingAdmin »

Very common problem. See: viewtopic.php?f=11&t=30797
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Sipho
Posts: 5
Joined: Sun Apr 25, 2021 6:44 am
Location: South Africa
Motorcycle: GL1100 '81

Re: Burnt wires

Post by Sipho »

I've bridged it (for now) with 380V wires. Started it, revved it, let it idle. No problem. It charged. Will take it on a run tomorrow. If all goes well, will have to get proper connector and problem solved. Why it works like this, my technically retarded brain has no fookin clue. Thank you.
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WingAdmin
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Posts: 22236
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (sold)
1998 XV250 Virago (sold)
2012 Suzuki Burgman 400 (wife's!)
2007 Aspen Sentry Trailer

Re: Burnt wires

Post by WingAdmin »

It's not the voltage that's the problem, it's the current. High voltage wires are generally rated higher voltage because of their insulation. You can put 100,000 volts on a wire the size of a hair if you like, as long as it has sufficient insulation.

Wires that carry current are sized by gauge - which indicates the thickness of the metal conductor inside. Generally you should be putting 14 gauge wire in there. If the wire is undersized (i.e. 18 or 20 gauge) it will heat up from the current, and potentially melt.


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