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Run / Kill Switch Wiring XJ550 1981

Discussion in 'XJ Technical Chat' started by Doug_Ringwood, Jan 2, 2024.

  1. Doug_Ringwood

    Doug_Ringwood New Member

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    upload_2024-1-2_15-47-13.jpeg upload_2024-1-2_15-47-13.jpeg upload_2024-1-2_15-47-13.jpeg upload_2024-1-2_15-47-13.jpeg I think the PO has wired the run/stop switch backwards. The Red/White run/stop loop wires have been extended (in red) and wired to 2 of the run/stop switch terminals as shown in pic (the centre terminal and one of the outer terminals). The two "outer" terminals are also shorted together.
    So with the switch in the centre position (Run), the loop is disconnected. With the switch in either Stop position, the loop is connected.!!
    Does anyone have an info on how this should be wired?
    Thanks in advance
    upload_2024-1-2_15-47-13.jpeg
     
  2. Doug_Ringwood

    Doug_Ringwood New Member

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    Sorry about that - clearly hit a bit trigger happy width attaching the pics.
     
  3. Roast644

    Roast644 Well-Known Member

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    You've got something odd going on there. Almost looks like the back of the switch is broke and somebody did a repair? Here's what it should look like. There are just two terminals, plus the mounting screw. If the two terminals are jumpered together, it's permanently "on" rather than backwards.

    [​IMG]
     

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    chacal likes this.
  4. Doug_Ringwood

    Doug_Ringwood New Member

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    Thanks Roast644. Yes certainly something odd. I took the switch apart, managed to glue the broken parts back together and it still works backwards. Seems the run position has no terminal - maybe this has broken off in some way in the past. I can certainly live with it working backwards, just thought I might be able to figure out how to get it working correctly.
     

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  5. Minimutly

    Minimutly Well-Known Member

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    I don't know if this makes any difference but beware that the Haynes manual has the run/stop and start switches labelled up incorrectly.
    Its been a while since I stripped the switch so sorry, can't help you.
     
  6. Melnic

    Melnic Active Member

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    I pulled apart and cleaned my '83 XJ650 run/stop switch and start push button recently and took pics.
    I also pulled apart my '78 XS650 but did not take pics. They are very similar with some subtle differences.
    You may notice in my pic, I'm missing the tiny BB that belongs on the spring detent. without that, the switch can vibrate and rotate.
    I ended up buying a box of 100 BBs from Amazon as my search through the garage and kitchen failed.

    The 2 leads should SHORT when in the center as the 2 silver dots line up with that copper piece, then OPEN when pushed left or right.

    Now, when you turn the key switch, then move the run/stop switch, you SHOULD hear a click from the relay (safety relay?) that checks for the clutch pulled in, bike in gear, sidestand.
    Here is the test I do (if I recall correctly):

    Sidestand down, neutral,clutch out turn switch to RUN = click
    sidestand down, in gear, clutch out turn switch to RUN no click
    sidestand up, in gear,clutch in, switch to RUN = click
    Sidestand up, in gear, clutch out, switch to RUN no click
    Sidestand up, neutral, clutch out, switch to RUN click
     

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    Last edited: Jan 4, 2024
  7. Doug_Ringwood

    Doug_Ringwood New Member

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    Thanks Melnic. Looks like the rotating part of my switch is the same as yours with the copper strip and 2 dimples.
    The rotating part of mine though looks different having 3 circular pads (dots) as opposed to 2 on yours. No wonder mine works like it does. Weird, but I guess after 40 odd years, who knows what’s gone on.
     

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