Install of Aftermarket Rectifier in Remote Location

[FJ1100mjk]

Some of you may have previously seen the install of the Bosch Transpo Voltage regulator that I did. If not, here is the link to it...

http://www.fjowners.com/index.php?topic=10079.0

I did the install after finding the regulator was bad, but the rectifier had gone south as well.

Before I begin, I would like to state that there are easier installs of other aftermarket rectifiers and regulators.

I decided to do what I did, because I wanted to, had the correct and necessary tools, and gained the know-how for doing electrical work from other modifications such as: headlight relays, better horns with relays, voltmeter installs, accessory fuse boxes, and other things. I also don't mind the challenge of trying something new. Sometimes it comes out all right, and other times, well, you learn from both.

If you suspect that you have problems with your charging system, and have determined that the problem lies somewhere within the alternator, you can use various ways to determine what may be wrong with it by checking it out further. Have a look at this post where I (and someone else did later in the post) supplied a link to a Triumph forum that explains the procedures for learning about and checking out the innards of the FJ alternator. If your are going to replace either the rectifier or regulator, make sure the stator and rotor windings check good first.

Link to Demystifying the NipponDenso alternator:

http://www.fjowners.com/index.php?topic=10141.0

I bought the rectifier from Oregon Motorcycles Parts. The owner, Tony, is a great guy. The rectifier that I purcahsed, is their part/model number: R255a

http://oregonmotorcycleparts.com/rectifiers3p.html

The rectifier, can handle 55A. Plenty of excess for the FJ bikes.

For a couple of bucks more, you can have longer wires put on it, which I did. Mine were 30 inches long.

You could go even cheaper with something like this: http://www.windynation.com/products/accessories/conversion/rectifiers. I liked the cooling fins on the 80A, but it would've been a tight fit in the location where I placed mine.

Here's some pics of the rectifier (and regulator) installed...






For the rectifier, the three yellow wires were connected to the three bare wires underneath the alternator's cover. These connections were made with "magnet wire" splice connectors from Mouser http://www.mouser.com/ the part number is 571-623082. Magnet wire is what the windings of the alternator are made of. Google "magnet wire" to learn about it. Or not.

Red wire on the rectifier, goes to the red wire on the main harness, where the connection for the red wire coming from the alternator used to go. I say used to go, because the OEM red wire coming from the alternator is removed in this mod. Black wire from the rectifier, is the ground for it, and I connected that with a "ring" connector to an engine case bolt/screw, but you can run it to the negative post on the battery instead.

Here's a pic of the alternator before making the connections and removing the OEM regulator. Note the three bare alternator windings' wires...



Here's a pic of the alternator with the connections made. I had to grind (yea Dremel!) the old solder lugs (what the bare wires were soldered to before the mods) off the old rectifier, so they wouldn't interfere and/or short the new connnections. Note the use of heat shrink tubing (red and black), that was used to protect and isolate the new connections made.

I passed the wires through a hole I drilled in the alternator cover, and used a rubber grommet and sleeving over the wires to protect them. Then a connector was applied to the wires' ends.



Here's a pic of the cover back on.



Here's a pic of the connector used to make the yellow wires' connections of the rectifier to the wires' run from the alternator. The connector is a three-way Metri-Pack 280 http://whiteproducts.com/sealed280.shtml The connector is rated for 30 amperes. Plenty for the FJ application.



The mod was not all that hard to do. Especially if you've already been done other electrical upgrades, have the tools, and acquired knowledge and confidence.

I mentioned tools, right? Do yourself a huge favor and buy yourself a good pair of quality wire crimpers. Like these:

http://www.easternbeaver.com/Main/Elec__Products/Tools/tools.html

I bought the Hero FRH-07. Yea, it wasn't cheap, but you could spend a whole lot more than that on a better pair. Like other good tools that you've spent good money on to do the job right, you'll always have them.

If you're planning on getting into doing wiring upgrades, and want good, tight, reliable connections, just like you see on your OEM wire harnesses, then you'll need a good pair of crimpers, and the correct connectors as well.

There are many places to buy quality tools, connectors, and such. Google is your friend for finding them, and the how-to's for doing wiring and connections correctly.

Good luck!