1989 FJ1200 Not holding/building a charge

[FJGiddyUpGirl]

Hello, Im a newbie to both the FJ and the Forum. I traded up to a FJ1200 from a 1989 Sportster.

I picked up this bike on Sunday. It had been sitting in a garage for 3 years (owner passed away) Started right up and runs incredibly tight for its age. On the way home is died. Bump started it, then imminent death.

Towed it home, replaced the battery yesterday, ran great for about an hour and then.... Well you know the story. D E A D !!  My first thought was to check the stator (ouch $500.00) is there any other reason or location to look before I rob a bank??

Thanks in advance
Kris

[copper]

Check the red alternator plug on the left side of the bike (Behind the side panel, Just follow the alternator wires.). It seems to be a common issue of it burning up. Easy place to start and can be repaired cheaply if that is indeed the problem.

[movenon]

Hello, Im a newbie to both the FJ and the Forum. I traded up to a FJ1200 from a 1989 Sportster.

I picked up this bike on Sunday. It had been sitting in a garage for 3 years (owner passed away) Started right up and runs incredibly tight for its age. On the way home is died. Bump started it, then imminent death.

Towed it home, replaced the battery yesterday, ran great for about an hour and then.... Well you know the story. D E A D !!  My first thought was to check the stator (ouch $500.00) is there any other reason or location to look before I rob a bank??

Thanks in advance
Kris

Welcome Kris. Hold on spending money until you do some more testing.. What makes you think it is the alternator ?  How are you set up for area and tools to work on the bike ?  What year is your FJ ?  Where are you located approximately ?  There might be another FJ owner near by that can help you.  Could be as simple as fuel cap not venting.  If it dies again, crack open the fuel cap and see if it starts.  

George

[movenon]

Check the red alternator plug on the left side of the bike (Behind the side panel, Just follow the alternator wires.). It seems to be a common issue of it burning up. Easy place to start and can be repaired cheaply if that is indeed the problem.

This is what the connector looks like.

Without more info it could also be the voltage regulator.
George

[fj1289]

Kris - definately need to do a little troubleshooting and preventative maintenance before resorting to parts swapping.  

One of the "free" harbor freight multimeters could save you a bundle here!

Check and clean battery connections and the alternator connector already mentioned.   Odds are it is fried -  you can cut out the bad connector and direct connect the wires with good quality butt connectors to remove that failure mode in the future, BUT you will have to cut wires if you need to remove the alternator in the future.

Is it charging at 2000 RPM or so?  How many volts does it show across the battery terminals at 2000 - 3000 RPM?

Then, if it is not charging you can start troubleshooting the voltage reg, the rectifier (both built into the alternator on the FJ) and the condition of the brushes and the stator...

None of this is difficult, but does need to be done somewhat methodically.  

Check and clean/repair the connections and get back with us what the voltage reads -- then someone can assist you with the next steps

Chris
oh - and welcome!

[FJmonkey]

Welcome Kris, too bad you don't live closer or I could help you with your new FJ. I just picked up an '89 myself after owning an '86 for the last 18 years. Don't just look at the connector, pull it apart. Mine looked mostly normal till I cracked it open.

Looks good on the outside....


But melted on the inside...




The fix is simple, cut the offending connector off and crimp on new spade connectors. Make sure you mate the connectors so you can't miss-connect them. Each side gets one each male and female connector. This helps if you ever need to pull them apart in the future. 

Keep posting, we will help you get your FJ sorted out and running in the Kookaloo zone... Just in time for the West Coast Rally.

[Pat Conlon]

Now THAT's a good idea Markus, alternate male/female ends so as not to reverse the connection.

So simple. 

You guys know the reason that connector fails....right? 

Overcharging

[FJmonkey]

Now THAT's a good idea Markus, alternate male/female ends so as not to reverse the connection.

So simple. 

You guys know the reason that connector fails....right? 

Overcharging

FYI, that is a Randy RPM fix, just passing on the good info. Spending time with Randy and his sons at the shop can be a really good learning experience. Not to mention a great way to spend time wrenching on the FJ.

[ribbert]

Now THAT's a good idea Markus, alternate male/female ends so as not to reverse the connection.

So simple. 

You guys know the reason that connector fails....right? 

Overcharging

FYI, that is a Randy RPM fix, just passing on the good info. Spending time with Randy and his sons at the shop can be a really good learning experience. Not to mention a great way to spend time wrenching on the FJ.

I don't understand this, is it so you can't push the plug together the wrong way?

Noel

[Pat Conlon]

Cut the melted red plug off (2 wire) and install spade connectors....alternate m/f so you don't plug the wrong spade together

[craigo]

Cut the melted red plug off (2 wire) and install spade connectors....alternate m/f so you don't plug the wrong spade together

Exactly how I modded mine. You mix these wires up and there's hell to pay.

CraigO

[aviationfred]

+1 for the spade connector advise for replacement of the RED connector.

For electrical connector replacement and lighting mods. I have used Molex brand connectors, easily sourced from Radio Shack. They come in 2,4,6,9 and 12 pin versions.

Also I ordered this kit from Aerostitch. ALL the connectors in the kit are the 2 pin type, but there is 3 sizes.

http://www.aerostich.com/tools/electrical/tools-connectors/aerostich-92-piece-molex-connector-kit.html

Fred

[ribbert]

Now THAT's a good idea Markus, alternate male/female ends so as not to reverse the connection.

So simple. 

You guys know the reason that connector fails....right? 

Overcharging

FYI, that is a Randy RPM fix, just passing on the good info. Spending time with Randy and his sons at the shop can be a really good learning experience. Not to mention a great way to spend time wrenching on the FJ.

Aw, come on guys. It doesn't matter whether its male, female, gay, bi or transgender, the connector, like the thousands of other automotive electrical connectors in use and all the others on your bike, only goes together one way.

This deviation from accepted wiring standards is just setting up the mechanic or next owner for confusion, for no benefit.

You say it is to prevent incorrect connection, the plug already does that. It is addressing a problem that doesn't exist.

Find something that needs fixing.

Noel

[Pat Conlon]

Apparently, Noel does not understand what we are talking about........ 

[copper]

Red male alternator side to Red female Battery side.                 X ---> Y Red Wire
Brown female alternator side to Brown Male battery side.          Y ---> X Brown Wire

Presents no confusion what so ever as X will not connect to X and Y will not connect to Y.

Red alternator side will not longer connect to Brown battery side        X---X Red to Brown (No connect)
Brown alternator side will no longer connect to Red battery side         Y---Y  Brown to Red (No connect)

Speaking in electrical spade connecter terms that is.