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Discussion Starter · #1 ·
My friend’s ’97 SE has a months-long issue of dying on the road after a varying amount of time riding, sometimes hours, sometimes less.

His battery was kind of old, so we replaced it with a new AGM battery. Now we also just installed a new alternator. All that new stuff and the same problem still exists!

After the new alternator and battery, he rode for a couple of hours last Saturday and then stopped for dinner. Got back on the bike to head home and it refused to run. It would start, but refused to continue to run. Today he rode about a half an hour and the same thing happened. Stranded on the side of the road.

What’s going on here? What’s left in the charging circuit that could be causing this?

Any help would be greatly appreciated.
 

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More info & symptom details would be helpful, why are you thinking that this is an electrical issue? It sounds like it also could be a fuel related issue, plugged filter, bad fuel line, or fuel pump Etc.
 

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Discussion Starter · #3 ·
More info & symptom details would be helpful, why are you thinking that this is an electrical issue? It sounds like it also could be a fuel related issue, plugged filter, bad fuel line, or fuel pump Etc.
New fuel filter, new air filter. The bike will run down the highway for an hour at speed just fine before the symptoms occur. Could not do that if it had a plugged fuel filter I don't think. Next day it will do the same!?!

But now that you say maybe not a charging problem, perhaps an ignition problem. Remains a mystery.
 

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Discussion Starter · #6 ·
Try bypassing the fuel shutoff valve.
Alex, color me confused. I did not know there was a fuel shutoff valve or fuel petcock on the GL1500...

EDIT: OK, found it in the service manual. We'll check that out. Thanks.
 

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If the fuel pump gets hot they stop when the fuel get low the pump gets hot. someone will know more on here and help you.
The fuel pump on a 1500 is in the gas tank and is kept cool by gas. When it heats up it will exhibit those symptoms. If you check the fuel shutoff and its not the problem there is a cheaper alternative to OEM to get you back on the road. You can find the instructions and materials you'll need here:

http://www.berrysweb.com/Documents/GL1500_FuelPump.pdf

And that's a good reason to keep your tank at no less than 1/4. Less than that and you risk fuel pump deterioration and, eventually, failure.
 

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Discussion Starter · #11 ·
OK, back with more information:

The way he gets the bike running again after it dies the last time is to put the battery on a battery tender and charge it. Then it will run again for some time before dying.

Last night we got a VOM out and checked the voltage out of the new alternator. It was 11.8 Volts. That's not enough to keep the battery charged. Honda service manual says it should be between 13.5 Volts and 15.5 Volts at the alternator output.

Looks like his brand new alternator is bad right out of the box. He's gonna call them with the test results today and have them send a replacement.

Will report back when the second "new" alternator is installed.
 
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