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82 1100 GL plug melted

chuck hahn

chuck hahn

Forum LongTimer
Past Site Supporter
I have a problem..the plug that has the right hand switch plugs into the wiring harness has melted. I tried to look at the wiring diagram on Cliffs website but even with my glasses its kinda blurry to read. If anyone has a better clearer diagram or cann tell me what colors go to which i would be most grateful. I am assuming that the rectfier/reg had lost ground at some point and it melted the plug.
 
I tried to follow the diagram. I am not very good at reading wiring. So i will just forget it. I think that maybe it wopuld be best to just get the plung and patch it in.. i just cant get it to do anything.
 
chuck hahn said:
I tried to follow the diagram. I am not very good at reading wiring. So i will just forget it. I think that maybe it wopuld be best to just get the plung and patch it in.. i just cant get it to do anything.
Click to expand...
Well, you have to determine what went wrong, so you can't forget it or the wind will be still! Is this melted plug under tank or in headlight bucket?
 
Tom..here the story from the start. I got the bike running really well but had no charging voltage. I took my meter and had 74 volts across all three stator legs..good stator. So i deduced it was a bad reg. I went to the dealership and talked to the head mechanic that i know and he told me to check the white plug down by the right hand coil. He said that when regs go bad and loose the grounds they have a tendency to melt the plug. Well i pulled the tank and sure enough found the fried plug. I also got a new reg. I decided to get new male to female connectors and rewire it that way. There is a wire in there that is a jumper..grey loop. I got it all messed up and cant figure out whats what. Being color blind isnt helping me any either. I would rather buy a plug with both ends in tact and wire that in. I am color blind in shade of colors.
 
The goal here is to get the charging issue solved so i can sell the bike. It is solid and just needs some good cleaning and tires, but i wont sell anything thats not at 100 % functionality.
 
In the diagram..i am assumingb that IGNITION COIL means the igniton switch that youn put the key in??
 
chuck hahn said:
Tom..here the story from the start. I got the bike running really well but had no charging voltage. I took my meter and had 74 volts across all three stator legs..good stator. So i deduced it was a bad reg. I went to the dealership and talked to the head mechanic that i know and he told me to check the white plug down by the right hand coil. He said that when regs go bad and loose the grounds they have a tendency to melt the plug. Well i pulled the tank and sure enough found the fried plug. I also got a new reg. I decided to get new male to female connectors and rewire it that way. There is a wire in there that is a jumper..grey loop. I got it all messed up and cant figure out whats what. Being color blind isnt helping me any either. I would rather buy a plug with both ends in tact and wire that in. I am color blind in shade of colors.
Click to expand...
OK, I grasp the problem of color blindness with wiring. But I think the only part of regulator circuit that goes thru that plug would be related to a stator phase running up and back thru the left hand switch- do you still have this setup or are all three stator phases now going direct to your new R/R?
 
chuck hahn said:
In the diagram..i am assumingb that IGNITION COIL means the igniton switch that youn put the key in??
Click to expand...
To me that diagram is pitiful, but ignition coil is not the ignition switch! Hopefully someone with direct knowledge of this bike will chime in shortly.
 
I havent done anything with the new reg..its still in the box. I got one from Rick Electrics. When i found the melted plug, i figured that was the most important thing to correct or i would just be chasing my tail otherwise. I was gonna eliminate the plug and just put male / females in each wire and call it good. I have opened up the switch and cleaned all the contacts for the kill switch and the starter button. I am gonna sell the bike for just what i got in it. I replaced the frayed clutch cable, got the new reg, and got a new..in the box ..oem tank. I got 350.00 into it and it runs. Now this electrical isuue has it dead.
 
Oh..and a side note..I know power is goping thru the kill switch. When the key is on and i flip the switch from run to stop, i can see the lights on the cluster dim and brighten.
 
I am looking at the one on the link that matchless posted..its for an 83 and not an 82 though. The one on cliffs website is of very poor clarity to me.
 
Anyone with this bike, can you take some pics of the white plug thats under the tank that the right handlebar switch plugs into. I can maybe use that as a template to see if i can get the bike sorted out. I think it has a 5 or 6 pin connector there. Should see a blue one there also..i need the white one.
 
There is an owner's manual you can download at BikeCliff's site. That way you can keep zooming in 'til it is easy to see. There is a legend at the bottom that explains what abbreviations mean as far as color. The ignition switch is in the lower left corner. The same manual seems to cover '82 and '83
 
the wiring diagramm at his site suxx. the lore you zoomm the worse it gets.. I am just gonna sellmit asm is and someone willm have a good sound low milage bike.
 
Okay chuck, for one thing you should bypass the factory harness and wire the stator direct into the R/R. For the R/R output, you can either feed into the harness (which sends the electrons though the old fuses box) or wire the R/R output direct to the battery with a fuse in-line. That out-and-back loop to the hand control has fried more GS harnesses than anything else I've seen.
 
ED..i wash my hands of it..its for sale and one of the electrical geiuses here can fix it ..or it can sit in the back of the gargae and rot..but i aint touching it..the dealership mechanic told me that when the regs loose their grounds and fry that they send too much unregulated current and to check the white plug under the tank to see if it was melted..and when i checked it , it was melted.. The root cause of the problem was the regulator frying and messing up the plug with too much current and heat. I got the new regulator, but without the wires rehooked together properly its useless..and i cant follow a wiring diagram and my colorblindness is a problem as well. so i throw my hands in the air and surrender it to whatever fate awaits it.
 
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Hey chuck, your choice of course but it sounds like you are frustrated and giving up. It's pretty easy work to bypass that plug, only the important wires need to be tended too, not the stator wires which are the ones that get hot. Let me know if you change your mind and want to fix it. A bike like that with only 20k miles is worth more than you are asking. Since you are not working yet (I assume) why not just treat it like a job and try to get as much as you can?
 
I am very frustrated Ed.. Especially since i worked my azz off and fixed everything that was broke or rusted shut. Then i get it running real sweet, not a tick in the engine..i mean it just purrs smooth as silk. Then the reg fries and melts the wiring harness. I admit i am easily defeated by the electrical stuff. I was all stoked that i got the new clutch cable and an air filter. I wanted to just redo the wires and i got it all screwed up. Its my fault , so what am i to do?? Best thing is to hire someone to come over and undo my crap or get rid of it. Once the electric is back online it will be a rider right out the door. And here i am and dont know anyone close to ask for help.
 
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