Help with turn signals, and break lights on 80 XJ650

I just got this bike from a friend, because he got something bigger. The bike run ok, but has no turn signals, or brake lights.

The tail light does come on though, and the guage lights work aswell, but no brake lights. Plus the headlights broken and needs replaced (What a mess) but a boat load of fun IMHO 8O

I've looked around the bike for loose or broken anything, but seems as though everthings in order. Stuck a brand new battery in it, and it starts right up. What gives :idea:

 

For the turn signals: Check the bulbs first. Then fuses. Then the switch...2 screws and it comes apart and off the handlebar.
For the brakes: Do they not come on when you try either the front or rear brake? Check the bulb (both elements). Then check the brake light switch located on the brake lever (there is one for the rear brake too...just look for it). You can push it in by hand and the light should come on if the bulb is good. For the front brake lever it usually gets gummy in there where the switch is.

Best of luck.

 

Hey thanx for the responce, but as far as the brake switch goes, i tried to make the brake light come on by hand by tuggin on the switch and got no responce.

I also had the signal switch apart poke'in around in there, and noticed the little white piece of plastic sliding from side to side while i moved the switch, but nothing hapened there either, even though the switch slides back to the middle whether i move it left or right, and its kinds stiff when you move it, plus the horn wont work aswell.

 

theres a connector that runs under the tank on the left side beside the coil,it will be the big one.unplug it and clean it well.My 550 does the same thing.....

 

Ok kool, i guess ill have to venture my way under the tank.

 

Tail light gets its power through the Main fuse. Brake light and turn signals get power from the Signals fuse. I'd check the Signals fuse and the fuse clips themselves.

If you have an original fuse box in this bike, one of your first projects should be to replace it with a newer one that uses ATO fuses. The clips of the stock fuse boxes oxidize, lose conductivity, and also get brittle to the point where they will easily break when replacing a fuse or trying to bend the clips a bit tighter.

 

Yeah, the fuse block on this bike has the old style glass tube fuses in it, one for the ign, taillight, and the headlight, but the one for the headlight is broken because theres only one clamp on it left, the other side was just bouncing around the fuse block. The clamp part would be the little metal piece that the fuse slides into, not sure if the headlight works or not because it was busted out when i got the bike (which was a sealed beam).

The Yamaha parts depertment wants close to $80 bucks for a sealed beam for this bike, 8O so i visted a small shop about 10 miles away that has a lot of old bike parts, and i got one that takes a bulb, which i still have to get.

But in anyevent whats the best resorce for obtaining an ATO fuse block for this bike :?:

 

Chacal has them. Check under the XJ4Ever forum here.

Cheers,
Paul

 

Yeah thanx man, i found them after my last post :wink:

 

Here is the question do the brake light, signal lights and horn come on without the engine running? Unlike the headlight? I am trying to figure this out, without the engine in the frame.

I have replaced the fuse block with mini auto fuses.
I have brand new rear and front brake switches.
I have power to both sides of the fuse block at the signal fuse and new fuses around.
I do not have voltage to the chocolate or the dark green leads to the signals front or back
Nor do i have voltage to the horn.
The PO trashed the wiring harness and I have done my best to replace all broken wires and connectors.
The rear light/license plate light does come on.
I do not have voltage to the rear brake light switch...brown and yellow
Handlebar switches are in excellent shape and I did take apart and thoroughly clean all connectors with electronics cleaner.
I have a brand new battery with excellent charge 12v.
When i actuate the front brake switch i get a clicking in the relay under the tank....i assume this is normal...but no light.

Suggestions on checking without the engine running or in? Or can it be done at all? Anything I might have missed? My next thought was a broken ground but I have no idea where to start.

Cheers,
Marc
1980 xj 650 maxim

 

Do you have a wiring diagram?

I can tell you that you won't have power to the signals (chocolate and Dk green) until the flasher is activated; but that you should be able to turn the ignition switch to "on" and test the flashers and brake lights, at least on the 550s. But that's with the motor in the bike and a fresh battery.

Your bike may be a tad different.

 

I have all the xj wiring diagrams....i figured out a rookie novice mistake i did not have power across the fuse block at the signals. I had thought i checked it. I fixed that problem. Now the rear brake switch works and light comes on. Still no brake light with the front switch however. But it still actuates the relay. I hear a distinct click. I was thinking it was a bad relay. I have no power at the flashers even with the switch turned....and no horn. I do have power to the switches. Going to check next proper power to the under tank relay and flasher relay. I hope all this trouble turns out to just be those two. And since all these relays were just thrown into a box, and they have no color coding and part numbers rubbed off, its trial and error. But at least the rear brake light comes on so I am 1 for 600. And I have the XJ cds thats a big help. Thanks bigfitz.

 

OK I have fixed all my issues. I traced the problems to bad wires within the headlight bucket. I have one issue I have 3 brown wires within the bucket. 1 for the brakelight, 1 to the pilot box, main panel and, one on the main harness. How do these three get connected and to what? I have attached a photo to maybe help. Thank you in advance for the excellent help.

Marc

 

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