Wiring question

[ADHD Perfected]

I noticed allot of talk about relay mods, do FJ's have issues with high load circuits and is my 87 one of them. 

[The General]

I noticed allot of talk about relay mods, do FJ's have issues with high load circuits and is my 87 one of them. 

Nahhh....It`s not about high load circuits. It`s about Voltage drop that occurs with time.

The culprits are usually aging contacts and old wire connections mainly.

Any old vehicle suffers similarly, particularly if you are after optimum voltage for lighting or in some cases Spark for performance objectives.

The relay overcomes the "voltage drop" of the original cabling up to the handle controls and back, as well as associated contacts, plus any voltage drop caused by age and/or use. When Combined with new larger cabling direct to the battery from the relay, even more voltage drop is overcome from energy loss through smaller original cable.
 
Without a particular fault (eg crook connections, broken wire strands, dirty battery return through battery terminals or ground wire connection) your bike will still be reliable and with adequate lighting for compliance standards.   

[red]

I noticed allot of talk about relay mods, do FJ's have issues with high load circuits and is my 87 one of them. 

ADHD,

Modern electrical practice is to run things by relay.  The item gets a straight shot of power (relays click in, hard and fast), from the battery/alternator.  The relay is just the actual power switch, and if it is not up to the job, it's easy to upgrade the relay as needed to a heavy-duty version.  Switches on top of the bike are not so easy or cheap to replace or upgrade.  Since powering a relay needs less current than the OEM switch was intended to handle, the stock switches can last far longer in daily use.  Everything just works better, and OEM switches last longer, with relays.  Humans can't flip a switch as fast as a relay, consistently, and the slow contact (making and breaking) will dirty the electrical contacts inside the switch.  On a bike, replacing old switches can be expensive, but replacing a relay is peanuts, by comparison.

Especially on older bikes, relay installations can make a lot of sense.  Load handling will just be a matter of using wire heavy enough to deal with the current.  Using the stock wiring to control a relay makes a very light load on the stock wiring.  Only the power side of the relay (not the control side) needs wiring heavy enough to handle the headlights, for example.  The electrical path from the battery to the headlights can be much shorter, using relays.  Your bike is fine as is, but relays can make it better (maybe with better headlight output, and longer-lasting top switches).

Cheers,
Red

[Pat Conlon]

Well said Doug and Red, spot on...

[Mark Olson]

The ign relay mod to the coils is a big help in starting. After this mod is complete you will see improved starting when the engine is warm and it roars to life very easily. For your year fj there will be hard starting on the stock wiring when hot.

[ct7088]

Cleaned contacts on all the connectors and fuse blocks that I found with contact cleaner and toothbrush and then used DC4 electrical insulating compound to keep the dirt and moisture out. The head light seems brighter. The two pin connector with the red and tan wires was partly melted. Has anyone drawn in the connectors on the wiring diagram from the FJ manual?

[ADHD Perfected]

Thanks should be no problem wonder if they make sockets for four terminal micro relays, sounds like a trip to ebay.

[red]

The two pin connector with the red and tan wires was partly melted. Has anyone drawn in the connectors on the wiring diagram from the FJ manual?

ct7088,

Here is a thread with many sources for old bike connectors. 
With any luck, one of these places can help with a new connector.
http://www.fjowners.com/index.php?topic=12564.msg124845#msg124845

Cheers,
Red

[red]

Thanks should be no problem wonder if they make sockets for four terminal micro relays, sounds like a trip to ebay.

ADHD,

Once you have the right Part Numbers, Google can find you lots of retailers for electrical/electronic parts. 
Search by Part Number, and maybe Brand Name as well.
Amazon is a fair source of relays, and wired relay sockets.

Cheers,
Red

[ADHD Perfected]

Found this www.cycleterminal.com/relay-base.html they have micro relay holders that lock together. Should save on space and carry up to 30 amps enough to run anything on the bike.