Member Contributer CurtBrass Posted March 17, 2019 Member Contributer Share Posted March 17, 2019 New to the group; bought a 1999 VFR 800 last year. Ran great all summer but I was going through headlights like crazy. In the fall I rode out my driveway and it just died. Basically, no power to the fuel pump. FI light on, but couldn't hear the fuel pump whirring, starter would engage but it wouldn't fire. I figured an FI problem. Put it away for winter, and started looking at it now. The large 30 amp fuse beside the fuse block was melted. Replaced it. Tried starting. Cooked the 20 amp FI fuse. Repeatedly. Checked orange earth block, all looked good. Checked three yellow wire connection downstream from the R/R and it was cooked. Absolutely black and destroyed inside. Cut out the connection and reconnected the wires. Fried another FI fuse. So I'm guessing that the R/R is shot. I've seen suggestions about replacing with an R1 R/R, but what about all the other wires? And any any thoughts on the headlight issue? Or is it likely related? Link to comment Share on other sites More sharing options...
Member Contributer MBrane Posted March 17, 2019 Member Contributer Share Posted March 17, 2019 New battery, stator, R/R, and bypass the stock charging system wiring. It's the only way to be sure. Link to comment Share on other sites More sharing options...
Member Contributer CurtBrass Posted March 17, 2019 Author Member Contributer Share Posted March 17, 2019 I have a new battery, happy to replace the Stator and R/R, but how do I bypass the charging system? Link to comment Share on other sites More sharing options...
Member Contributer CurtBrass Posted March 17, 2019 Author Member Contributer Share Posted March 17, 2019 Any suggestions on the best Stator and R/R to install? I'd rather do it once and do it right than have to do it again. Link to comment Share on other sites More sharing options...
JoelF Posted March 17, 2019 Share Posted March 17, 2019 Headlight bulbs could have been related, possibly too-high voltage. You'd have measured the voltage to see but that'd be before all this other damage. I'm planning to install a knockoff FH020AA unit I got for $30 (USD) from a USA vendor. There are lots of writeups on this. A genuine version is $130 or so, I'm game to try out a knockoff but not the even-cheaper ones direct from China, too much of that stuff I find are QC fails. Link to comment Share on other sites More sharing options...
Member Contributer MBrane Posted March 17, 2019 Member Contributer Share Posted March 17, 2019 I have had the 847 kit on my '99 for a couple years now. That, and an Eastern Beaver headlight relay/accessory fuse block kit. Takes a huge load off the wimpy stock wiring. Link to comment Share on other sites More sharing options...
Member Contributer CurtBrass Posted March 17, 2019 Author Member Contributer Share Posted March 17, 2019 Ok. So I've ordered the FH020AA from Roadster Cycle and the relay kit from Eastern Beaver. Should I order a stator as well, or is it probably ok? It seems like it will be a real pain to replace. Link to comment Share on other sites More sharing options...
Member Contributer CurtBrass Posted March 18, 2019 Author Member Contributer Share Posted March 18, 2019 Pulled the stator cover and found a very burnt brown stator behind it, so ordered a new stator as well. Will let you know how it all works out. And on St. Patrick's Day, this is as close to green beer as I'll get. Link to comment Share on other sites More sharing options...
Member Contributer MBrane Posted March 19, 2019 Member Contributer Share Posted March 19, 2019 How long stators last depends on a lot of factors, but those of us who ride agressively in warmer climates tend to burn 'em up sooner. I have found the OEM units to be of better quality than aftermarket replacements. Link to comment Share on other sites More sharing options...
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