Repairing Solenoid Wires

[Jbone90]

Hello,

Recently I bought an 1986 gl1200i. Was riding great until one day I was warming up the bike for a ride. The bike started well, but as soon as I put on my stereo deck and turned the stereo power on the bike stalled out and I could start up again since.

I checked out the battery and when doing so I noticed the connector to the solenoid was melted and one of the wires were corroded off (please see photo). Each wire underneath were also wrapped in electrical tape and seemed to have been twisted onto the original copper wiring, as if a repaired was made before.

I was wondering I go about repairing the solenoid wires in order to get my motorcycle up and running again? As well, could a weak or failed battery have caused this?

Thanks

[Aussie81Interstate]

I would start by checking your main fuse located underneath the solenoid plug - remove the plug first and open it up - it could be your main problem... but I would be getting those solenoid wires - resoldered properly and it is a bit difficult to see the yellow stator wires behind don't look that brilliant either. Clean up all your electrical connections as well.

good luck

[Jbone90]

I would start by checking your main fuse located underneath the solenoid plug - remove the plug first and open it up - it could be your main problem... but I would be getting those solenoid wires - resoldered properly and it is a bit difficult to see the yellow stator wires behind don't look that brilliant either. Clean up all your electrical connections as well.

good luck

Thanks for responding.

Just checked the fuse attached to the solenoid and looks ok. Do you know if there a way to get new wires and a push connector to attached to the fuse in order to repair the wires?

[Aussie81Interstate]

Looking OK and being OK is not the same.

Do you have a test light or a multimeter?

You should be able to source another connector quite easily - you could see a junk yard and just cut off the connector and wiring you need from another similar harness, or if the connector is OK on your harness then just pop the wires out and fix those by resoldering a new section of appropriate coloured and gauge wiring in place- that means you have to do a good soldering job and then make sure you have good clean connections and cover with heat shrink - make sure you slide the heat shrink over your wires before you solder them together - I have even put 2 layers of heat shrink over - to be sure to be sure.

cheers

[Jbone90]

Unfortunately I don't have a multi meter and the connector with the wires on the fuse is melted. After doing research however everyone seems to say the dog bone fuse is 30amp but my bike fuse says 50amp. Could this be the culprit of over heating??

Looking OK and being OK is not the same.

Do you have a test light or a multimeter?

You should be able to source another connector quite easily - you could see a junk yard and just cut off the connector and wiring you need from another similar harness, or if the connector is OK on your harness then just pop the wires out and fix those by resoldering a new section of appropriate coloured and gauge wiring in place- that means you have to do a good soldering job and then make sure you have good clean connections and cover with heat shrink - make sure you slide the heat shrink over your wires before you solder them together - I have even put 2 layers of heat shrink over - to be sure to be sure.

cheers

[Aussie81Interstate]

Fair chance that is one of the issues - sticking an overrated fuse where a maximum of 30amp is required - only leads to overcoming a short term problem- which then eventually shows itself somewhere else... maybe the PO kept popping fuses - didn't try and find or source the problem - just over compensated - and now you have the problem of sorting it out...

good luck with it... you need to buy yourself a cheap multi meter- learn how to use it - lots of simple how to's on the internet - then start probing your system and you will soon work it out...

do you have a soldering iron? if not again look into buying a cheap one - it will be your friend - and you can fix lots of smaller electrical issues with knowledge on how to solder two wires together..

cheers

[Jbone90]

Thanks! I will give your advice a shot! Appreciate your help.

Fair chance that is one of the issues - sticking an overrated fuse where a maximum of 30amp is required - only leads to overcoming a short term problem- which then eventually shows itself somewhere else... maybe the PO kept popping fuses - didn't try and find or source the problem - just over compensated - and now you have the problem of sorting it out...

good luck with it... you need to buy yourself a cheap multi meter- learn how to use it - lots of simple how to's on the internet - then start probing your system and you will soon work it out...

do you have a soldering iron? if not again look into buying a cheap one - it will be your friend - and you can fix lots of smaller electrical issues with knowledge on how to solder two wires together..

cheers

[CrystalPistol]

Honda had a updated revised plug that hooks to that starter solenoid as well. OEM the current to run the bike goes through the connector twice. The revised connector kept that path .... but added another one within the plug so current had two paths, one without going through that plug twice. My connector was good, I simply added the jumper wire as indicated.

[Jbone90]

I've ordered a new solenoid with fuse and plan to rewire. My issue now is though that the solenoid fuse had 4 wires, each pair different size wires. I need to figure out what guage they are to get new ones to solder for repair as the current ones are two short after trimming the burnt ends.

Honda had a updated revised plug that hooks to that starter solenoid as well. OEM the current to run the bike goes through the connector twice. The revised connector kept that path .... but added another one within the plug so current had two paths, one without going through that plug twice. My connector was good, I simply added the jumper wire as indicated.

StarterRelaywireingupdate1998800w_zpsf823ef9d.jpg

[CrystalPistol]

The revised plug kit had wire pigtails of correct color codes.