Hardwiring the 3 yellow Stator Wires

[sparky65]

We're finding many or most of the GL1200 owners know about this important fix to save the Alternator from burning out because of that friggen plastic plug.What we are also finding is that many are also frying the plastic Plug on the other end of those wires which is connected to the regulator. There's only a couple of feet of yellow wire between the two plastic plugs and if one goes the other may not be far behind it so hardwire both ends. My buddy a true Goldwing mechanic by trade showed me a box of fried plastic plugs yesterday and many of them were from the other plug. "Heads Up".

[neoracer]

seems that LTD/SEI are more suspectible to rectifier connector problems since they have larger current going thru them,same with the connector at the solenoid,believe that everyone still having stators could benefit overall by hardwiring all three connections sooner than later
shortly after getting my SEI the same problem was apparent and cured by hardwiring 20K ago,although have found several types of ato auto fuseholders that were not up to the task for the solenoid mod

[bs175dths]

I was able to coax another 30K miles out of my stator/regulator by removing the three yellows from the one plug at the battery and giving them new individual plugs. I also physically seperated the plugs to additionally reduce heat buildup.
Newly soldered pins, new plastic plugs, dielectric, and a seperation of plugs bought me some miles before the inevitable happened.
I am on a strict budget and needed to coax out as much as I could before taking the plunge!

[CrystalPistol]

In my case, it wasn't the plastic plug's fault. The heat was generated and the plastic melted the most in the area of plastic covering the portion where the terminals in the plug are crimped to the wires. 16 years ago when I replaced my stator I also replaced the plug with a kit from Honda, it was same as stock .... except I removed each terminal from the plastic and soldered the crimp to eliminate resistance. I also ran new 12 ga wire in yellow, all the way to the regulator/rectifier bypassing the upper plug all together. I recall the wire from the reg/rec unit here were steel wires, not copper .... so after stripping and wrapping them, I slid short sections of brass tubing over each splice, crimped with pliars, then soldered each, then applied the shrink wrap and some tape all cinched with a zip tie.

I also packed my stator plug with dielectric compound and upon completion, plugged it together and then taped it up partly because it was near the battery vent tube and corrosive gasses maybe. I check it by unwrapping at least once each season, snug up the female pinchers, apply a tad more dielectric, and put back together and wrap in tape. So far, absolutely no discoloration, no melting, just clean shiney brass male and female connectors.

[admin]

We're finding many or most of the GL1200 owners know about this important fix to save the Alternator from burning out because of that friggen plastic plug.What we are also finding is that many are also frying the plastic Plug on the other end of those wires which is connected to the regulator. There's only a couple of feet of yellow wire between the two plastic plugs and if one goes the other may not be far behind it so hardwire both ends. My buddy a true Goldwing mechanic by trade showed me a box of fried plastic plugs yesterday and many of them were from the other plug. "Heads Up".

Honda should have used water cooling on those yellow wires and plugs. LOL

[bs175dths]

We're finding many or most of the GL1200 owners know about this important fix to save the Alternator from burning out because of that friggen plastic plug.What we are also finding is that many are also frying the plastic Plug on the other end of those wires which is connected to the regulator. There's only a couple of feet of yellow wire between the two plastic plugs and if one goes the other may not be far behind it so hardwire both ends. My buddy a true Goldwing mechanic by trade showed me a box of fried plastic plugs yesterday and many of them were from the other plug. "Heads Up".

Honda should have used water cooling on those yellow wires and plugs. LOL

I read somewhere (here) the acid in used engine oil can damage the insulation of electrical windings, so water cooling an electrical system is a more better idea. ('more better' was used on purpose)

I am joking, just joking. It is just a joke!!

Actually, maybe a larger gauge wire would have solved the problem.

It is a small inconvience for such an otherwise excellent design.

-Ride On