|The ORIGINAL GL1200 Charging
System Repair Harness™
IMPROVED DESIGN - THE PLATE - DETAILS
Does your Honda GL1000/ GL1100/ GL1200
Interstate, Aspencade, LTD, SEI have any of these symptoms?
these symptoms are caused by a chronic motorcycle problem - bad wiring.
engine hard to start
and backfire when cold
or whine (stator) in AM/FM radio & intercom, multiple stator and/or
stator connector replacements
melted or burned
terminals on the starter solenoid
spikes up when stopped or overheats in parades
oil turn black too
yellow, blue or rusted just past the heads
an engine with hydraulic lifters
case temperature is less than 100°F or over 140° F
over 240-300°F on idle
less than 14.5 volts or more than 15 and/or dead battery
Repair many or all of these problems
and prevent severe engine damage with the
Original GL1200 Charging System
About 1992, I spent 200+ hours reverse -engineering the electrical
system in the GL1200 and proved the above symptoms are usually caused by
one thing - defective electrical connectors. In the older bikes like the
CB 360-750s, this caused loss of engine performance and a dim headlight.
This, plus the fact the charging systems couldn't keep the battery charged
put many motorcycles out back to rust out.
of the Harness.
In 1989, I bought a 1986 GL1200 Aspencade still in the
factory shipping crate for about $6500. Why was it still in the crate and
so cheap? It nearly killed me the first week of ownership when the left
chrome spark plug cover dumped water in the plug well and a cylinder cut
out in a busy intersection. If not for racing experience, the GL would
have been run over by a truck. Within a few months, it was running poorly
and hard to start, backfiring so bad that the clock in the dash was destroyed.
Since an oscilloscope showed severe electrical interference on the charging
system, I decided to put my extreme talents in electronics to use.
The Goldwings were too expensive to suffer that fate!
The GL 1200, like many other motorcycles (at least all the Hondas
I've owned from 360 - 1200 have had this problem) run low on charging system
voltage which results in weak ignition and poor engine performance and
overheating. Corroded and oxidised electrical contacts drop voltage on
the way to the ignition coil, as a result, the coil sees about 6 - 9 volts
instead of 14.5.
So why not repair the connections? There aren't a few
connections- there are over 60 connections including regulator and
fuse block that must be repaired, and it's impossible to fix them all unless
the entire main harness and all
the electrical devices that connect to it are replaced. Just for
a round figure, try $4000.00. And what you get to replace it with is already
starting to deteriorate from age because its laid in a warehouse for 20
I tried everything possible to repair the old terminals including
un-crimping and soldering them to the wire, nothing worked.
I invented the ORIGINAL GL1200 Charging System Repair Harness
about 1990 -it solved most of these problems. It was rigorously tested
it on two GL1200s here in NW Ohio. Once those tests were passed, the Harness
sold itself with basically no advertising (despite attempts by American
Honda and GWRRA to suppress it) with the help of the American Goldwing
Association (AGWA- excellent group), Fred Rau, Editor of Road Rider Magazine
(Motorcycle Consumer News) and Gene at Saber
Cycle. Fred Rau of MCN was an electrical engineer who recognized the
value of the Harness, and published it in the Road Riders New Products
column in March 1993. During this time, I served as National Technical
Director and Author for the American Goldwing Association (AGWA),
which published technical articles on my electrical, electronic and mechanical
work on the Goldwings.
Design improvements, 12/06
THE ORIGINAL HARNESS
IS TOTALLY REDESIGNED!!
* Easier to install, cleaner installation
* Uses the Original type Fuse Links
* Convenient mounting point for fuses *Stainless
mass made 'electrical connections
crimped connectors to fail like
other "harness" designs."
* FOR ANY CYCLE !
improved version gives the same performance benefits as before, but now
with a cleaner,
neater installation. The original type main fuse link
is used for the same fusing characteristics as original design. The ignition
coils are protected by a separate fuse to prevent a transient fault from
killing the engine. The Plate can be used to connect accessory power without
messy connections to the battery.
The waterproof insulating Plate mounts behind the battery in a vibration
resistant mounting. A fuse link can be added for
the Voltage Regulator protect it from damage. All connections
are soldered or bolted with Stainless Steel hardware.
© 1992-2013 David R. Campbell.
No one has permission to reproduce
this information except SABER
CYCLE to whom thanks are due
for referring this page. There are
no "authorized agents" nor anyone authorized by me to reproduce or
sell The GL1200 Charging System Wiring