Age!!! Diodes don't last forever. Bad grounds can accelerate the demise of the RR.@Rednaxs60 I think I found something.
I was testing the bike, put on another main fuse, connected everything back and saw a little bit of white smoke out of the RR and then everything seems "normal"
The fuse stays good with ignition switch off. I can turn the bike on and all electricals seems working as expected.
So the culprit is that the RR failed somehow and created a short circuit inside? Is it a not-too-uncommon thing for RR to fail? What are the possibilities a RR fails?
I would like to learn more about why RR would fail before installing a new one
Looked at the schematic in the Electrical Troubleshooting Manual. Connectors look like your pics from too much current flowing through, and can also be because of dirt/grime over the years - excess heat build up. These ground connections are how the RR dumps excess power to ground. If the RR is failing, mainly the comparator circuit - set point should be approximately 14.2 VDC, the RR could be dumping excess power to ground.
I would strip back the wiring harness and inspect the ground wires. If the ground wires are in good condition, the probable cause is dirty connections. You can do a test of the system by disconnecting the green ground wires form the RR connector and using a new ground wire, connect it to the battery ground and observe the operation of the electrical system voltage. Definitely need to replace the connector.
You should test the RR to determine the health of it. If the RR test is good, my vote is for dirty connector, it is 36 or so years old, nothing lasts forever, and probably has not been serviced on a regular basis. An older bike is no different than an older car or a trailer. Grounds are a nemesis.
This should be what you need; 7.7 MB file on MEGAOne other thing is, The electrical troubleshooting manuals I found for GL1200L all missing dozens of pages including the page 157 for RR. Does anyone has a electrical troubleshooting manual which contains these pages?
PM sentHi, I have a ton of stuff for a ltd. I purchased a non running bike and the old timer made me take a limited that he had that was mildly crashed. he had it for 30 years. It had 3,000 miles on it. I have complete wiring harness, dash with 3,000 miles, lower fairing in nice shape. Complete fuel injection assembly. Sold engine. I have the electronic boxes and many other things. I have bought,fixed, solde 75 plus gl 1200 bikes but only fooled with a few limiteds. I will give any one a great deal on everything.