stator wires size

Information and questions on GL1200 Goldwings (1984-1987)
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Motorcycle: 1986 GL1200 Aspencade

stator wires size

Post by oldishwinger »

Hi Folks,

I need to solder the three yellow stator wires, on my 86 apsy, and I may need to use additional wire, to bridge the gap.

advise on what size wire, and its amperage, would be very much appreciated.

Many thanks.

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Re: stator wires size

Post by virgilmobile »

I personally recommend a minimum #12 stranded....#10 stranded is preferred....
Do check the plug at the regulator module first....corrosion and overheating can happen there too.
If it's also poor,you can bypass(not use) the original 3 yellow wires and string 3 new ones in it's place.
If you do this,try to keep the 3 wires the same length.
I have seen 3 new #10 fine stranded wires used to replace the bikes wiring due to the black oxidation on the copper,making it near impossible to get solder to stick to it...
The 3 yellow wires are AC does not matter which one goes to what terminal.

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Re: stator wires size

Post by Ace1Hunter »

It is very Important to put the same gauge of wire for the stator wiring because they can burn up the wire is wrong gauge. My dad made this Mistake and the wires around where different gauge wires burnt up and the stator. The Goldwing he gave me.

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Re: stator wires size

Post by flash1942 »

Virginmobile is right.In theory you can go larger wires but smaller ones may get you into trouble. #10 to 12 stranded would be my choice. Length is not critical unless you are talking about 40 feet !! It's AC current at that point so the voltage drop will be nil for a bike. PLEASE do remove the plug and solder and heat shrink the wires. And as always IMHO.

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Re: stator wires size

Post by HawkeyeGL1200 »

The last two I did I used #12 multi-strand conductor wire. I agree that #12 or #10 should be perfectly fine. I used wire I had on hand... It is also VERY important to make sure you get rid of all the corroded wire so you get good adhesion between the solder and wires...
I am wrong as often as I am right concerning what is wrong with someone else' motorcycle without having seen the machine in person. Guessing with limited information, as to the source of the trouble, is sketchy at best.

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Re: stator wires size

Post by sirgkm »

Question: rather than solder the three yellow wires from stator to the three yellow going to rectifier, could one just run three yellow wires from stator Directly to rectifier?

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Re: stator wires size

Post by CrystalPistol »

I put a new stator in my '85 in 1997, I also installed a new Honda plug kit down near the stator to replace the melted OEM. I carefully removed each wire from the plastic plug housing and soldered the wire to the terminal where factory was just a crimp. I did this with all 6 terminals, then I plugged the plug together with dielectric grease in it and wrapped it. Checking it several times over the years, it always looked freshly done. On the bike side I substituted three long pieces of yellow insulated 12ga. multi strand copper wire to reach the regulator/rectifier. I had noticed that where the three yellow wires from reg/rec entered the plug with the other several wires near the reg/rec, there was evidence of excessive heat there so I cut these three yellow wires, found they were not copper, they seemed to be steel stranded wire. I slid heat shrink over each wire as well as a larger piece over all three, and a piece of brass tubing. I did a careful job splicing the 12ga. copper to the steel, slid the brass tube in place, crimped it, soldered then, then slid the heat shrink in place, did each one, then a wrap of tape and the larger heat shrink over the group. Never another issue … sold bike in June '19.

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