82 1100 GL plug melted

[chuck hahn]

You can if you want..I just listed it for sale..really cheap.

[Nessism]

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.

[chuck hahn]

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.

[Nessism]

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?

[chuck hahn]

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.

[chuck hahn]

take one of all 4 sides.. I am at a total loss here.. I cant find any solid orange wire in the harness..I see two orange with white stripes and the one thats highlighted with the red tube tag.. the others look pretty straight forward..white with red tracer to white with red tracer etc etc. And hwat was the wire that was connected with the jumper wire?? It all just basically fell apart when i had to pry the melted plastic apart.

[chuck hahn]

Heres the melted plug..its literally fused together. The "plan" was to cut one wire on each side of the plug..use male/ female connectors and rewire it and cut the plug out of the wires..well i got it all jacked up and there was a jumper that went between two wires and i dont know where that goes either.. I dont know if anything downstream got damaged and i suspect i cant tell until i get these wires sorted out so power is routed prioperly..

[chuck hahn]

the two jumper..grey and white..what wires are connected to each jumper..that i think is whats messing me up. When i pried the plastic apart they fell out and i didnt get to see what they were jumping together?

[chuck hahn]

Anyone wanna decode it and just tell me what wires hook together?

[chuck hahn]

john..I really appreciate the efforts..i cant follow it in segments as i am scrolling.. I am done with it all. I am not gonna mess with it anyore..I will unly get it worse and make myself all that much more angry. I dont thinkm ahead a lot of the times and if i had i would have got the camera and took pics of it BEFORE trying to resplice the melted mess..now i got a dead bike that pretty much useless to me.

[chuck hahn]

Ok..I need to just stop. The one wire harness runs up to the left handle switch with the turn signals switch.. I lost the ball bearings in that switch and i just am compiling more damage..I thank all that tried,but i now have areal mess and its time to part out the bike.

[tom203]

Ok..I need to just stop. The one wire harness runs up to the left handle switch with the turn signals switch.. I lost the ball bearings in that switch and i just am compiling more damage..I thank all that tried,but i now have areal mess and its time to part out the bike.

Ok, just stop and take a break. I just pulled the wiring diagram off Basscliffs. It's confusing and would be frustrating to a color blind person, but it's similar to all bikes of this vintage. Let us know if you decide to carry on- plenty of folks here to help!

[chuck hahn]

Tom and John..yeah i would love to get the bike running again. I will now need a used left hand switch to replace the one i ruined this morning. SAnd i was thinking that maybe if someone has an old harness that i could buy the plug from the main wiring harness and put that in the harness. I think that if all the colors match i could ( in theory ) just put the new plug in and then plug in the other left hand switch. I got it all jack out of shape now. I am pretty disappointed with myself right now.

[tom203]

Tom and John..yeah i would love to get the bike running again. I will now need a used left hand switch to replace the one i ruined this morning. SAnd i was thinking that maybe if someone has an old harness that i could buy the plug from the main wiring harness and put that in the harness. I think that if all the colors match i could ( in theory ) just put the new plug in and then plug in the other left hand switch. I got it all jack out of shape now. I am pretty disappointed with myself right now.

Stuff happens! left and/or right switches come up all the time on ebay, I bought one last fall $10. To replace that burnt plug, you could just use individual connectors. Looking quickly,four are all that's needed. That plug had a dummy stator loop (up and back) , but you will eliminate this useless feature when you wire in the new R/R. But please find someone who is not color blind to be your eyes!

[chuck hahn]

Tom..I am laughing a bit at myself here..The whole thing started with the intent to eliminate the plug and use individual male/female connectors..thing is when i pried the melted plug apart i got the wires all confused. Then on top of that i lost my grip on the turn signal switch and all the springs and such went flying off in the grass somehwere. I figure that if i can get the left hand switch, then at least i will have one side of the plug with the wires intact. Now i am so skittish becuase i dont want to do any more damage. I think i will talk to the dealership mechanic i know and see if he wants to make a few bucks doing a side job.. cant hurt to ask.