Gen 3 Gets FZ-1 Fuzeblock, Erica Lights, and The "Big Drill"

[Ignacio]

I'd wired my Gen 1 bike with a conglomeration of Radio Shack terminal strips, added as I went, and it worked pretty well--even if it eventually became a birds nest.

With the Gen 3 I have an opportunity to start building an eventual birds nest from scratch as well as do thing differently than I did before. Still aiming for the goal of reduced clutter the cockpit area. There's also just not the same amount of spare room in the nose of the later Gen bikes. So, made the call of going with an FZ-1 Fuzeblock and placing it under the seat.

It get's a 12 gauge wire and 30 amp fuse from the battery and look at this--I have only ONE addition to the battery. I think I counted 5 ring terminals on my old FJR and had to opt for longer fasteners. I'm bound and determined to run all auxilliary items through the Fuzeblock.

Technically, I installed the Erica lights first, but nothing came together until after the Fuzeblock install. 5% and just on the edge of the light beam.

I decided to place the dimmer switch (it goes to whatever level I set on low beam and 100% on high beam) in the glovebox as I'm pretty sure I'll be leaving it on a 5%/100% split.

100% and on the edge of the light beam again. These suckers put out some serious photons.

Here you can see where the additions are in the cockpit area. The left PowerLet is for electric clothing and inflator in case of a flat tire and companion knob on the box on the clutch reservoir is the clothing controller. The switch on the same box is the on/off for the Ericas. The right Powerlet will be for my powered tank bag and double as charging port for the Battery Tender. The loop of wires on the left are to power the GPS and planning to take-off a lead for my Littlight.

Still a fair amount of work to do. I want to encase defacto wiring harness segments into split loom. One piece is done as it transits the engine bay.

And I have a little project when this is done.....I have to drill a hole in a perfectly good fuel tank, install a bulkhead fitting, and piece together a recently converted Gen 1 fuel cell to the new bike.

The gallons that have flowed through that chunk of aluminum.......

I did a quick estimate and think it's been over 2500 of them so far!

 

[Mudslide Miller]

Nice pics of your project Iggy. I've been working on similar things with my PDM60. I like your easy-access powerlet locations but I would definitely have an aversion to drilling into my beautiful red plastics for fear of screwing it up. I mounted my Krista switch on top of the battery cover and the dimmer switch on top of the right brake reservoir. I like having access to the dimmer; a little brighter for daytime idiot cell-phone-using cagers and at minimum at night, so as not to blind oncoming traffic. Even the Kristas put out some bad-ass light, I can only imagine what the Ericas will do. Since you only have the fuzeblock going directly to the battery, where did you tap in to the hot side for your right powerlet since it obviously has to remain hot for the Tender.

 

[griff]

Iggy - I would be interested to know how you locate the fuel fitting on your main tank. I was all set to put on a fuel cell on my old grey Gen 1 and then went and bought my gen 3 Ginger. Are you using the same fuel cell you had on your Gen 1?

 

[BigOgre]

Nice pics and ideas, I know it will help when/if the time comes in my garage. I had the same question that Mudslide did about the Tender and the FZ-1 also. And along those lines, you going with a voltmeter of some sort?

 

[Warpdrv]

FUZEBLOCK is such a nice addition to streamline the installation of those must have additions... That is the only thing left for me to do on my 15...

Nice work looking good

 

[DustOff]

Awesome. Where did you tap the low power switched line?

 

[escapefjrtist]

Good looking installation Matt. You've given me a couple more ideas for my lowly 'ol beat up GEN II.

Thanks for sharing your ideas with the collective!

--G

 

[DustOff]

I believe I answered my own question....https://www.fjrforum.com/forum//index.php/topic/160666-relay-trigger-power/?p=1187884

 

[Niehart]

I mounted my Krista switch on top of the battery cover and the dimmer switch on top of the right brake reservoir. I like having access to the dimmer; a little brighter for daytime idiot cell-phone-using cagers and at minimum at night, so as not to blind oncoming traffic.

+1

Matt, have you noticed any major differences between Gen I and Gen III wiring?

 

[JamesW]

Sanitary installations for all the must haves, George and Marcus will admire. My only, KISS principle, must have, is my escort. Oops, forgot the heated jacket liner/tire pump connection.

 

[Ignacio]

I did think a while about drilling the plastic, but saw Warchild did it with success and looked pretty good.

Since you only have the fuzeblock going directly to the battery, where did you tap in to the hot side for your right powerlet since it obviously has to remain hot for the Tender.

The power does go all the way from the battery to the FZ-1 (12 gauge main wire on a 30 amp fuze),back again by the battery, and then to that right Powerlet. I've used some marine grade tinned wire sized according to some charts I found. That one is only a few amps so I used a 16 gauge wire for the Powerlet run. Good idea about checking voltages though before I button it back up. After a certain Seahawks/Packers game that is starting soon.

 

[Ignacio]

I believe I answered my own question....https://www.fjrforum.com/forum//index.php/topic/160666-relay-trigger-power/?p=1187884

In my case I used the cigarette lighter in the glove compartment. I also used it for the Ericas.

 

[Ignacio]

Matt, have you noticed any major differences between Gen I and Gen III wiring?

Some similarities and some differences. Mainly is the feel that positions of stuff are all different. I look and see a relay brand name and think I saw that on the Gen 1, but was 2 inches left. Things feel like they went through a funhouse mirror and moved everywhere in the nose especially. But the truth is other than tapping a low-power line to power the ignition (using my rarely used cigarette lighter) and adding two lines to the battery I'm not even touching the stock wiring system. Heck, I even used an extension pigtail for the high beam tap and didn't modify it.

 

[Ignacio]

Iggy - I would be interested to know how you locate the fuel fitting on your main tank. I was all set to put on a fuel cell on my old grey Gen 1 and then went and bought my gen 3 Ginger.

Next project. I'll need to do back-and-forth to make sure I pick the best spot and may have to tweak the Jiffy-Pop a bit. My initial guess is somewhere inside the indention area.

Are you using the same fuel cell you had on your Gen 1?

Yep. As I shared:

piece together a recently converted Gen 1 fuel cell to the new bike.

 

[101stpathfinder]

I like the bulkhead fitting arrangement, custom built?

Can you give the specifics?

+1 on the lights, they almost require some type of sound effect when switched on. On the way to EOM with the wife, I would say "Whop"

Waiting patiently for the drill and install thread on the tank! I haven't got to mine yet…

 

[Ignacio]

I like the bulkhead fitting arrangement, custom built?Can you give the specifics?

I got them from Bill McAvan before he passed away. One came with the cell when I bought it new in about 2005 or 2006 and installed on my first FJR. I bought a 2nd with the intention of installing it on the other '05, but never did. Glad I didn't and left it in the drawer until this FJR.

I haven't seen this particular fitting in my travels...so I don't know where to get it. I kinda remember somebody suggesting maybe Sampson or Jazz might have something, but never looked.

I didn't end up drilling this weekend, but I did update various fittings on the cell to ensure everything uses 3/8" hardware. Then I went through with a 9/32 drill bit and made sure every orifice was at least 0.28". Several non-drillable elbows and the bulkhead fitting orifice were well over 0.30".

Compared to the original setup several spots (the old fuel filter in particular) was as small as 0.21".

So, by my math I've increased the potential flow rate by about 63%. Given the limited pressure head on a gravity feed system--I'm hoping for a little quicker transfer rate in application.

 

[101stpathfinder]

I like the bulkhead fitting arrangement, custom built?Can you give the specifics?

I got them from Bill McAvan before he passed away. One came with the cell when I bought it new in about 2005 or 2006 and installed on my first FJR. I bought a 2nd with the intention of installing it on the other '05, but never did. Glad I didn't and left it in the drawer until this FJR.

I haven't seen this particular fitting in my travels...so I don't know where to get it. I kinda remember somebody suggesting maybe Sampson or Jazz might have something, but never looked.

I didn't end up drilling this weekend, but I did update various fittings on the cell to ensure everything uses 3/8" hardware. Then I went through with a 9/32 drill bit and made sure every orifice was at least 0.28". Several non-drillable elbows and the bulkhead fitting orifice were well over 0.30".

Compared to the original setup several spots (the old fuel filter in particular) was as small as 0.21".

So, by my math I've increased the potential flow rate by about 63%. Given the limited pressure head on a gravity feed system--I'm hoping for a little quicker transfer rate in application.

Have you chosen a QD and measured it? This was one area where my selection could be improved.

I think the bottle neck in the flow occurs there. What are you choosing and what is the measurement through

the QD? I think I am going to rebuild the whole tank to tank configuration on the '08. Jim (flab) tried to talk me into

a QD under the main tank, and I would not have it (Tight with $) … I think he knew best. Its a real PITA for maintenance without one.

I had the very same fuel filter before the IBR, but cut it out along with some extra hose trying to solve the issues.

On the 200cc.. I have a gas cap (Main Tank) that I can pull the key from while opened, so I would leave the cap cracked open under

the tank bag when the heat started kicking in. Also I would open the valve a few degrees with a new fuel fill to prevent the lock

from occurring… seemed to work in all but one instance.

Also it was suggested to me that I run a T valve out of the Aux. with a hose that will reach the main tank and/or the tank of another

bike- I really liked the idea in case of emergency. My Aux tank cover (LindaTs) has a pouch in back where I could coil the tubing.

BTW- I think the bulkhead is Gen. specific- You might need to pass it to me while you look for a Gen. 3 fitting!

 

[RossKean]

Just a comment on the fuel filter...

If there is ANY air in the filter, you will end out with substantially reduced fuel flow with a low pressure gravity feed. Not much of a problem if the filter is completely filled with fuel. I doubt that the flow from a non-pressurized feed would be sufficient to purge all of the air out of the filter.

 

[Ignacio]

Have you chosen a QD and measured it? This was one area where my selection could be improved.I think the bottle neck in the flow occurs there. What are you choosing and what is the measurement through

the QD? I think I am going to rebuild the whole tank to tank configuration on the '08. Jim (flab) tried to talk me into

a QD under the main tank, and I would not have it (Tight with $) … I think he knew best. Its a real PITA for maintenance without one.

I had the very same fuel filter before the IBR, but cut it out along with some extra hose trying to solve the issues.

On the 200cc.. I have a gas cap (Main Tank) that I can pull the key from while opened, so I would leave the cap cracked open under

the tank bag when the heat started kicking in. Also I would open the valve a few degrees with a new fuel fill to prevent the lock

from occurring… seemed to work in all but one instance.

Also it was suggested to me that I run a T valve out of the Aux. with a hose that will reach the main tank and/or the tank of another

bike- I really liked the idea in case of emergency. My Aux tank cover (LindaTs) has a pouch in back where I could coil the tubing.

BTW- I think the bulkhead is Gen. specific- You might need to pass it to me while you look for a Gen. 3 fitting!

I have a 5/16" CPC/Colder from the old system and ordered a larger 3/8" unit. (Those wondering where these things come from....try this website for models and this website for good prices). I'll measure when I receive it.

I'm not sure I'll be able to use the same drill trick on it and agree it's likely the next constraint. I may run without one as I've found a vise grip pinched on the hose near the fuel filter, off at the cell valve, and quick redirection into a spill jar works pretty well.

I'll ponder a T valve arrangement. I haven't ever needed it before.

f there is ANY air in the filter, you will end out with substantially reduced fuel flow with a low pressure gravity feed.

I know. I've never not had air and hope it will be a proportional flow rate. I've thought about running without a filter, but having essentially a second fuel tank I think it's more prudent to have one.