What's this green plug for?

[86FJNJ]

I ordered the safety switch. Do my markings on the safety switch look correct? The part I am not 100% positive about is in the instructions the red wire is "to switched 12v" which I would imagine is the "RUN" switch on my handle bars, correct?

But one side of the purple loop says "To Battery + OR switched 12v" on the diagram. For now I've marked that as going to the positive starter solenoid connection, does that sound correct?

The written instructions seem to clarify further by saying "The larger ring terminal can be used to attach one purple wire to the starter solenoid as a good source of battery power. The other purple lead would be wired to the positive lead on the fuel pump.

[86FJNJ]

Is this the starter solenoid? If so I will attach one end of the purple loop to this, correct?

[86FJNJ]

If I am attaching the red wire on the safety switch to the RUN switch on the handle bars, I see there are two wires going to the switch, I guess to close the circuit. Does it matter which of the two wires I connect the red wire to? I'm thinking one would always have power and one wouldn't and I would need to connect to the one that doesn't, is that right? Or does it not matter?

[86FJNJ]

For the green wire on the safety switch which is suppose to be connected to the tachometer, I see there is one grey wire coming off of one of the coils and through the connector it goes into two grey wires. According to the 1986 diagram one is suppose to be dark grey to the right turn signal and the other grey is to the tachometer but they are both the same color grey on my bike.

Rather than take the entire fairing off to see the grey wire that goes to the back of the tach I'm thinking I just cut one of the two grey wires and turn the ignition on. If the wire I cut was to the tach the right blinker will still work and that's the wire I need and I can repair the wire and connect the safety switch to it. If the wire I cut was the one going to the right blinker, the blinker wont work and than I can repair it and then connect the green wire from the safety switch to the other grey wire.

[Pat Conlon]

Seeing as now you are pulling your power for the fuel pump off your starter circuit (plenty of power there) and now all you need is a switched power leg....why not use your green plug as your switched power?
That would be much easier than the start/stop switch.

After all....that's  what started this discussion.

[86FJNJ]

Thanks Pat, if the green plug only gets power when the "RUN" switch is on then I guess that would work, is there a way I can confirm that? If that works I think I'm good with everything else I have to do. would it just be a matter of hooking up the two wires for the green plug to something like a light and if it illuminates when the run switch is on but not any other time I should be ok I think.

Assuming I don't use the green plug for california evap and instead wire per the instructions, what I'm unclear about is how I connect the red wire to the fuse box with the female connector and how that would be operated by the "RUN" switch.

Regarding the two grey wires and my need to tap into the one for the tachometer, I'm thinking rather than tap into one of the two wires from the plug I can just tap into the single grey wire that comes from the coil to the plug before that wire splits into two grey wires. Does that make sense.

[86FJNJ]

I'm pretty sure the green plug has power even when the run switch is OFF because I turned the ignition on and had the RUN switch off and stuck the two wires from the fuel pump in the green plug and the fuel pump kicked on.

I guess I could still use it because the safety switch wouldn't turn the pump on until the TACH is showing the engine is on, right?

So if I connect the red wire from the fuel safety switch to the positive wire on the green plug would I just leave the ground wire in the plug not connected to anything? I was going going to run the black ground wire of the safety switch directly to the frame but could I run it to the green plug? Or should I run the ground wire from the fuel pump to the ground on the green plug?

[Pat Conlon]

The aftermarket safety switch works just like the Yamaha oem safety switch used on the fuel pump FJ's.

When you turn your key on, the safety switch senses power from your green plug (before the engine starts and generates a tach signal) the safety switch turns on power to the fuel pump for only 3 to 5 seconds...then stops.
If you need to prime your carbs you may need to turn your key on and off a couple of times to fill your carb fuel bowls.

When the engine starts the safety switch senses a tach signal and as long as the safety switch senses a tach signal, the fuel pump stays powered.

When the key is turned off, power is off, the safety switch shuts off power to the pump.

 Here's the safety part of the safety switch....

Even with the key on....when the safety switch senses a stop in the tach signal like the engine stalled, or you were in an accident, the safety switch only runs the fuel pump for 3 to 5 seconds before it automatically shuts if off.


Hope this helps.

Pat

[86FJNJ]

Thanks for the explanation pat!

[Pat Conlon]

Sorry, I forgot to mention...

Yes, use the switched 12v power and the ground from your green plug.

[86FJNJ]

Finally did it. Installed the fuel pump and safety switch on my 86 converting it from gravity fed to fuel pump. I did utilize the green plug for the California Evap and it worked nicely. I took it for a 5 mile ride and no issues but it started to rain so I went home. I may make a post about the fuel pump mod for others who are interested after I have a bit more miles on it.

Is there a proper way to route the fuel lines for a fuel pump? or does it not matter on a fuel pump model?

Pat, thanks for your suggestion on the safety switch it really wasn't too bad to figure out.

[Pat Conlon]

Good deal, that green plug worked!
Having the safety switch pull the 12v power for the fuel pump directly from the starter circuit meant we didn't have to worry about pulling to many amps on the green plug circuit.

Congrats....You now have a real fuel filter to keep your carbs clean. Something we can't run with the oem gravity flow systems.

Alas, our gas tanks aren't getting any younger and as the title a great Neil Young album states: Rust Never Sleeps....

Putting your pictures together with commentary and saving this over in our Modifications Files will be of great help to your FJ brothers.

Cheers. Pat