Alternator

[Starquest]

Hello. Last week I removed the alternator for some maintenance and I saw a hole next to the flange mounting bolt hole that goes straight to the alternator winding. It's normal o I have to plug it

[Starquest]

I have a question. Why the alternator's o ring are different between years? The alternator p/m are the same for all years.

[FJmonkey]

Where do see different part numbers? 

[RPM - Robert]

84-88 has a wider o-ring and the 89 and up has a thinner o-ring. The alternator is the same part number but the body was changed. Just like the original 1984 and I think 1985 1100 had a two bolt alternator. Still the same part number because they are all interchangeable. The parts between the two may not be but if you buy the superseded number it would bolt right on to any FJ even it is is a two bolt engine the three bolt alternator would work.

Short winded answer. The bodies are different.

[Starquest]

The 84-88 o ring p/n is 36y-81642-50 and is 3.50 mm. The 89 on is p/n 2kt-8164250 and 2.40mm on thickness.

[Starquest]

Robert. I sent you the carburetors for cleaning. Did you received them yet? By the way, when I took my alternator off the bike, it had the thin o ring. Was leaking a little bit.  I tried to put the thicker o ring and didn't fit right. I did put in by tightening the bolts. It broke off.

[RPM - Robert]

Yes, I sent you an email regarding the carburetors last Friday. I will forward it again.

If someone put a later model alternator on an early model bike you would need the 2KT o-ring. The channel for the 36Y is deeper and wider, probably by about 1mm. Pictures are always helpful.

[Starquest]

I didn't receive  any mail. Are you sure you got the right e-mail? The deep of the groove is around 2mm and the wide around 2.75 at the bottom.

[RPM - Robert]

I would presume it is correct. I replied to the email that you sent me. You may want to check your spam folder. I resent it again this morning.

[RPM - Robert]

The deep of the groove is around 2mm and the wide around 2.75 at the bottom.

I would say you need the 2KT for your alternator. If it is only 2mm deep and 2.75mm wide the 36Y is 1.50mm higher than the outer edge of the alternator housing. Which is too much to try and force into the crankcase. It should slide in by hand.

[Starquest]

Ok. I'll try this weekend to work on the bike.A few things to fix,nothing major.The big deal is still I can't ride the bike for another 2 months after my achilles injury.Patience,patience.

[Starquest]

Well. I did put it yesterday the 2.40mm o ring on the alternator. It fitted good on the engine. I guess the P.0 changed the alternator for 89 up models. Mine is an 86.

[Starquest]

Doing some maintenance found the alternator and the ignition switch connectors melted.Check and pull them apart.

[aviationfred]

Doing some maintenance found the alternator and the ignition switch connectors melted.Check and pull them apart.

RPM sells the connectors with new pins for the ignition switch connector. http://rpmracingca.com/proddetail.asp?prod=M%2FC%3AIginitionPlugKit



Fred

[Starquest]

Thanks, Fred.I have the connectors.What kind of crimp tool I need for the connectors?