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Discussion Starter · #1 ·
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Dear Gurus

I have just got a new regulator for my GL1100I it fried and melted the plug.


Electrosport ESR290


My question is the yellow wires that run to the regulator all got hot and I was wondering if I should replace all the wires from the first plug by the battery all the way to the regulator and solder all of the connections.

Yes the plug by the battery was long ago changed to soldered connections. I was thinking that I might want to cut them out and run all new wires all the way to the regulator and then hard wire the voltage regulator in thus eliminating the melted male part of the regulator plug. (Or can I get a replacement plug for the wire harness)

Let me know your thoughts and or suggestions.

Thanks

Tib
 

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Monkey with a Football
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You can get plugs and terminals from electricalconnection.com, but I would probably solder them myself.
 

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Discussion Starter · #3 ·
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Would you replace all the stock yellow wiring too?????????

and while I am rebuilding the 81 GL1100I charging system should I replace any other wiring also, I know on a car that battery wires need changed from time to time does the bike need it?

I did replace the fuse link with a buss fuse. Thanks to someones suggestion. but the search is off line so I cant use it.:(

So ultimately if you know of a weak spot in any of the charging circuit for a GL1100 please list them here and I will address them all now to save me the roadside work later.

Thank you!

Tib:cool:
 

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just me but i soldered all those wires[ using existing wire ] and did away with plug all together, be sure you have clean wire, can dip in baking soda and water mix or as someone posted clr then rinse with clear water, dry then solder, flux can help for good connection. good luck:action::waving:
 

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3 things you need to get first : A ton load of patience,a wireing diagram,6 pack of beer. If you burned up the voltage regulator then you have a short somewhere.

Found my dead short in the fairing weight bucket after it wiped out biggest part of electric system.

Kidding about the beer!:cheeky1:But I needed every bottle to fix my problem.
 

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whoa fred patience and beer definately required, but the plug least wise on mine burny purely from bad connection, hope your's works out that way.:action::waving:
 

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Discussion Starter · #7 ·
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What started my charging system rebuild was she blew the 30 amp main fuse.

she would not hold her 30 amp fuse (key on or off) till I found the 2 touching yellow wires and the burnt plug at the regulator/rectifier separated them and removed the regulator.

The test showed that at least 2 of the diodes were gone as it would pass voltage both ways (red to green and green to red) 0.000000 resistance.

I would assume that it was caused by a bad connection that got hot in that plug. As when I got the melted plug apart the contacts were black and burnt for one of the yellow wires and that wire was welded to one of the other yellow wires. (dead short)

she started and ran on battery several times without the regulator to do the stator test and drive herself home from the store.

Is there a test that will tell me if my bike has excessive voltage/amperage draw?

Hope this info helps
 

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there is a test in ref. and faq. the search is off for now so you'll have to go through it, sorry:action::waving:
 
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