FJ Accolades.... PART TWO

[Mike Ramos]

Accolades.... Part Two...

First & foremost I wish to again express my thanks to Alan & Chris for their assistance (please review my previous post on this subject).  Also, honorable mention for MoveOn George & RPM for offering to overnight any parts that were needed.  Even Captain Ron was sailing into the vicinity to lend a hand; however luckily for him I was able to depart the day previous to his arrival...!

I had left Ouray, Colorado heading for Idaho at 2:00 am when the FJ suffered a complete electrical system failure.

Following is the listing of what was and was not damaged when the FJ had what seems to be a voltage spike.  Because so many components were involved, it is to a certain degree, conjecture as to what caused the initial voltage spike.  The cause and effect are sometimes difficult to separate and some is speculation....  For example, the CDI unit appears to have malfunctioned, but is that what caused the voltage spike or did it malfunction because of the voltage spike...?

Components that were burned out /damaged:

CDI unit – it would fire the ignition but would not power the fuel pump; additional internal problems may have occurred.
Large multi-pronged stock relay located next to the CDI.

Turn signal relay located behind the fairing (this was the one component not available so a standard automotive flasher was wired into the system).
 
Relay for the coils mod – because the relay burned, it may have saved the coils themselves from damage.

Relay for the fuel pump mod (installed at the same time as the coils) – perhaps also saved the fuel pump from damage.
 
Relay for the headlight mod - low beam only (the high beam was off so was not burned) – this is the Eastern Beaver H-4 wiring harness with separate relays for the high and low beams.

All light bulbs that were on, including the dash lights and LED rear tail light bulbs.

Components that appear NOT to have been damaged:

Interestingly NOT blown were the stock fuses for the flasher, head light and ignition circuits.  Eventually the 30 amp main fuse did blow, but only AFTER the damage was done. 

The WPS battery seems to be unscathed – I believe it has a low voltage shut down and apparently is protected by a high voltage protection circuity.

The large six prong stock fuel pump relay located on the side of the battery box was NOT damaged (perhaps because the relay for the mod burned first).

The starter solenoid is intact.

The recently installed ignition switch was disassembled & inspected and is in perfect working order.

The complete wiring harness was inspected and there are no worn spots anywhere.  Every connector was examined and was in working order; there are no corroded or burned prongs.  There was not a wire that shorted anywhere.  The accessory wiring was also inspected and is in good working order– all fuses were intact, none blew.

Questionable status:

The alternator – a used, low mileage replacement was installed in case there was a problem inherent with the original which may have caused the overcharge problem.

The voltage regulator – the used regulator available was not working so the one off of my original alternator was used – it worked for the 1,400 miles home without issue.

Contemplations:

The accessory side of the electrical is intact – the only accessory on at the time was the radar/laser detector which has built in low and high voltage protection.

The original alternator is being shipped to California for additional testing to confirm if it is operational.  Perhaps a definitive problem will be determined.

If there is a NOS CDI unit available, perhaps it would be advisable to install a new one.

Because there is no definitive cause, it may be prudent to eliminate the alternator from the equation; new FJ units are, to my knowledge unavailable.  I am contemplating the readily available XJR alternator – the modern technology would be beneficial - I m not sure if output is increased but it does bolt on without problem.

Details will be posted as they become available.

Ride safe,

Mike Ramos.

[Pat Conlon]

I wonder if you lost continuity in your generator's field wire? That and a failure of the voltage regulator would cause a massive overcharge voltage.
As I stated in the past (ad nauseam) I am not a fan of the FJ's internal voltage regulator.
It's in a bad neighborhood. Get it away from the engine heat and vibration.

Judging by Fred's write up, the XJR generator should be fine.

Let us know what you find Mike!

[Sparky84]

Absolutely Marvellous Mates you have there....

I am contemplating the readily available XJR alternator – the modern technology would be beneficial - I m not sure if output is increased but it does bolt on without problem.

Would the XJR alternator bolt straight into 84 model or only later ones?

[Mike Ramos]

Absolutely Marvellous Mates you have there....

I am contemplating the readily available XJR alternator – the modern technology would be beneficial - I m not sure if output is increased but it does bolt on without problem.

Would the XJR alternator bolt straight into 84 model or only later ones?

According to the RPM web-site, the XJR alternator will fit all FJ1100 and FJ1200 engines.

I should have the XJR alternator installed later this week.

Ride safe

[racerrad8]

It will work with either the 2 or 3 bolt alternator, the 2 bolt will just be missing the 3rd bolt. You do need the longer bolts that the XJR uses and the plug is different. Other than that it has the same bolt pattern and is clocked the same as the original.

Robert - RPM

[Firehawk068]

I believe that the Tachometer, and the Fuel Level Gauge also fried and ceased to operate?
Or was there something we overlooked when reassembling all the fairing connectors? (we did put some long hours in the wire harness)