Alternator failure

[FFGO]

I don't seem to be able to keep my charging system working.
1984 1100. I've had the bike a couple years and I keep repairing or replacing the alternator / generator.
I had the first alternator repaired and it failed. I had it repaired again (warranty). It failed again. Then I bought an eBay special and it seems to have failed this morning.
Each time I've installed the repaired units I've checked the charging system with a multimeter. The output tops at about 14.5 volts.
This morning the eBay special left me stranded in the shopping mall near my house. While waiting for a ride home I checked the battery connections. There appeared to be a lot of corrosion on the battery terminals. The battery was new last year and then charged and stored indoors fully charged.
I have a 'new' style Nippon Denso regulator on the shelf. I'll change that out but I thought I would ask here first to see if anyone can enlighten me on why I've had a series of failures.
TIA.

[FFGO]

Went back to get the bike with booster cables and the surface charge was enough to start it up. Actually it started 3 times in the parking lot and I never did use the jumper cables.
Evaluation at home shows the corrosion was actually left over baking sofa from prior cleaning and t/s.
Standing battery voltage is 12.4 right now and alternator output peaks at 14.3 volts around 4000 RPM and doesn't go beyond that, at least when I rev it up to 5000 or 5500.
Everything seems fine. IDK.

[Pat Conlon]

 Ohm check the brown field wire. This senses the battery voltage. If this wire is impeded the voltage regulator thinks your battery voltage is low and thus needlessly increases the charging current.
Speaking of Voltage Regulators, I am not a fan of the oem FJ voltage regulator. Due to its location it gets hot and then weird things start happening, like overcharging, cooked batteries, burned out light bulbs, etc. Testing the voltage output in your garage is not indicative of what happens on the road with everything heat soaked. I recommend the Transpo voltage regulator mod for all FJ's. Get that regulator away from the engine heat and vibrations. Instructions in the Files Section. Your battery and lightbulbs will thank you.

Cheers. Pat

[FFGO]

Thanks Pat!
I'll check out the brown sensing wire but I'm pretty sure it's all fine.
The heat could be an issue though as you mentioned. I'll look into that angle and see if I can nail it down.
Thanks again.

[Pat Conlon]

I forgot to mention, check your RED plug....overcharging causes this to melt.

https://fjowners.com/index.php?topic=19557.0

Report back. Let us know what you find.

Cheers.

[fj1289]

I forgot to mention, check your RED plug....overcharging causes this to melt.

https://fjowners.com/index.php?topic=19557.0

Report back. Let us know what you find.

Cheers.

And to add - the connector might look good on the outside and be crispy critter on the inside!

[FFGO]

I have changed the red connector previously. IIRC it looked good on the outside but was toasty inside.
I went back to basics and removed the accessory wires for the heated grips and trickle charger. The charging system seems to have sorted itself but I haven't done much riding lately. Then the clutch master failed and I just got that sorted. Rolling restoration! Good thing I love this bike. Haha.