Weird-a$$ Electrical Issue

[jwgeorge]

I have a really weird electrical issue going on with my 92 GS500E, with 8500 orig. miles.
OK, Here goes:

Running on center-stand, turn on turn signals, either side, doesn't matter.
Gauge lights stay strong, headlight doesn't flicker, turn signal works normal, voltmeter reads 12V.
Rev-up and voltage goes up slightly, .3 to .4V.

No problem, life is good!

Turn-off, restart on center stand, turn on turn signals, either side, doesn't matter.
Gauge lights get weak, headlight flickers, turn signal flashes like a strobe, voltmeter reads 12V.
Rev-up and voltage remains the same.
Now here's the punchline!!!!
Pull the front brake lever and the bike dies!!! Ta Da!!!! It's magic!!!

Sometimes the turn signals act up, some times they do not. No pattern, it's random.

Bad turn signal relay?
Bad ground somewhere?
Bad rectifier?

The last issue was fixed by cleaning a connection and applying dielectric grease.

Living in the humidity doesn't help the contacts from corroding.

Any help, anybody? Anybody?

Thanks,
Jay

[the mole]

Ok, some things were good, then they were bad, then you fixed one of them by cleaning some contacts.
I'm now as confused as your electrics! Can you be more specific?

1. What exactly did you fix, and how?

2. What is currently wrong and needs our input?

[jwgeorge]

Sorry, for the confusion, I fixed one problem, now the turn signal issue is what I am dealing with.
I found another post that suggests the ignition switch may have some internal corrosion.

The first problem was fixed by cleaning the ground connection for the rectifier.

The current problem detailed; turn signals flashing rapidly, headlight flickering, guage lights dim, dying when brake lever pulled.

I think that you were part of the other thread I saw from the end of Feb. 2009.
Some younger guy had a 94 that was having similar issues.

[jeremy_nash]

I would thouroughly check the ground connections, it seems you have an open ground somewhere

[mister]

I have no help to offer, but questions...

Does it do it if you use the back brake instead of the front?
Does it do it if you toot the horn instead of apply the brake?
Does it do it if you Flash your highbeams?

Michael

[the mole]

Given the age and lack of use of your bike, I'm guessing corrosion in connectors/switches is very likely your problem.
My suggestions:
1. Make sure the battery is fully charged.
2. Spray ignition switch with WD40 or similar, then turn it on and off a dozen times.
3. Get to as many connectors (and earths) as you can, make sure they're clean and a tight fit, spray with WD40.

Then report back to us! 

[sledge]

Some thoughts....
First off.....get the battery properly load tested at a shop and rule it out. Failed or failing batterys can behave in unpredictable ways and the symptoms can be misleading. Static tests mean nothing, its how it performs under load that matters and this can only be determined with the use of suitable test equipment.

If the battery proves to be ok the problem can only be down to bad grounds and/or poor connections somewhere and you have to hunt them down in a methodical way. When you check the various connections also make sure that the cable itself is securely held in the terminal and not loose.

Not likely to be the reg/rect or any other charging component. If they fail its generaly for good and not intermitant.

If you have a spare jump-lead or a length of heavy cable use it connect the negative side of the battery directly to a clean spot on the engine. This will by-pass some of the normal ground connections, see if it makes a difference. Then try it directly onto the frame. Another possibilty is the bracket that holds the reg/rect to the frame, make sure all the fixings are clean and tight and that the reg/rect itself is secure on the bracket as it uses it as a ground connection.

Check the taillight bulbs and holders too and make sure they are all clean and nothing is shorting out in there including the dual filliments inside the bulb itself.
If the bike has got very wet, relays can develop condensation internally and this can cause shorts between circuits. Try substituting them for known good ones. If you shake them next to your ear you can sometimes hear any water sloshing around in there.

Nothing worse than intermittant faults like this.....keep at it, you will find it in the end  

[jwgeorge]

Michael,
here are the answers I have for you:

"I have no help to offer, but questions...

Does it do it if you use the back brake instead of the front? - Didn't try the back brake
Does it do it if you toot the horn instead of apply the brake? - Didn't try the horn
Does it do it if you Flash your highbeams? - Didn't flash the highbeams"

But, I will do that this weekend and see what happens.
Thanks, for the ideas.

[jwgeorge]

To All,
I am thinking that it probably is a corrosion issue.
I will do the WD-40-ignition switch trick, then try to clean-up as many connections as possible.

It's supposed to rain here all flippin' week, so I have time to mess with it.

Jay

[jwgeorge]

OK, To all of those who sent suggestions and wanted feedback, It's Fixed!!!!
I finally got a chance to go out and do the WD-40 thing with the ignition switch.
I started the bike and it ran like usual, the headlight blinked with the turn signals.
Shut it off and it didn't want to start, acted like the battery was low.
Put the charger on the battery and came back an hour later.
Turned the key on and nothing, no lights, no nothing. Hmmmm.
Used the charger to help start it.
While running checked the voltage at the battery and it was slowly decreasing??
Would decrease faster when the engine was revved, well, must be a charging issue, right?
Taking the charger clamps off and on made the lights come on and go off.
OK, So moving the battery side to side in the battery box made the power go on and off and emitted a small electric arcing sound.

Turns out that the connection of the positive battery cable to the starter solenoid was loose!
I tightened it up and it starts and runs better than before.
The intermittent power loss wasn't a ground issue after all!!!!

Thanks to all for the ideas and put this on in the book of possible solutions!