imported post
77GL1 wrote:
Here's my theory....I think Honda knew how much heat was being put out, and use aluminum in the hope of dissipating heat. The three wire plug coming from the stator is frequently melted on the GL1000s and other models. I'd like to know for sure because it might be a bad idea to replace the wiring from the stator with anything but wire with real good heat dissipation.
77GL1, there shouldn't be ANY heat put out. If that wire is sized correctly it shouldn't heat up. On your 1000 the charging system is only 300 watts so that is less than 8.5 amps per leg. Those wires- be it copper, aluminum, or steel should be able to handle 8.5 amps AC easily.
Even then, if Honda wanted to dissipate heat they wouldn't cover the wires with an insulator covering. Remember aluminum wiring would carry less current than a similar sized copper wire.
Anyways the problem isn't with the wire (I haven't ever seen one burn the wire apart), it's with the terminals & connector. What happens in the terminals build resistance (due to oxidation, battery acid, too small, or whatever),, then the terminals burn & turn black,, then they lose current carrying ability & connection& build more resistance yet,, then the connector melts,, then the terminals touch each other & short out,, then the stator burns..
I'm not exactly sure what those wires are covered with (could be silver or any of the other alloys). But they do solder (aluminum won't solder)..
Twisty