Only cranks when it wants to.

So I finally got all the parts to my maxim and was excited to put it together today and hopefully take it around the block. One issue. I was trying to start it up and it was cranking over (it's been sitting for a year). After attempting to start it up for a little while it suddenly stopped cranking. The lights still come on. I disconnected the battery and made breakfast. When I came back to the bike I checked the fuses (still has old fuse box) and re connected the battery. To my surprise it started right up. Ran for about 2 mins. And then acted as if I hit the kill switch. Turned the key off. Back on. Lights come on. And it doesn't want to turn over. I'm thinking I have a bad connection somewhere. I opened up the kill switch and it looks spotless inside with near new wiring. I really want to get this running but am at a loss for why it's acting this way.

 

Check the fuse box closely. You may have a broken or at least weak clip holding a fuse. That might cause high resistance or bend away from contacting the fuse. This is a starting point. Keep in mind that any electrical system requires a good battery. Make sure it is fully charged and can maintain at least 10 volts when actually cranking the engine. A fully charged battery will be in the area of 13 volts. Keep us informed, maybe we can go step by step to locate fault.

 

...either that, or a woman has come back, re-incarnated as an 81 XJ650! 8O

 

Upon further inspection the clip for the ignition fuse definitely needs to be replaced. I will replace and let you know if it gives me any other trouble.

 

Make sure you have gas in it......I know it sounds stupid but it happens to alot of us and we get focused on a bunch of other areas to look.

 

If the fuse does not fix it you might want to check the starter button assembly for corrosion or ill fitted pieces.

 

You will. The other three fuses.

You can rebuild the fusebox with new clips from Radio Shack; or you can replace it. XJ4Ever carries the recommended blade-type replacement box ideal for these bikes, plus he has the OEM style in a plug-in version if you really want to retain the stock appearance. Good luck finding short glass fuses locally. (Experience; I stayed "stock.") Replace it, either way.

The original clips were made of some mystery-metal and then plated with the silver coating, whatever it was. The two react over time; the clips actually crystallize and will break, all on their own for no bloody reason whatsofreakingever. Known Achilles' heel of these bikes.

 

You should also inspect the Alternator Brushes.
Very simple chore.
Remove the Cover and measure the two Brushes.
10mm or less = replace.

Contaminated Starter Electrical end.
Carbon Dust from the Starter's Brushes contaminates the Commutator and Housing.
The Starter fails to Spin because the Current finds an easier path to Ground.

You can move the Housing away from the Motor enough to direct a Electrical Contact Cleaning Spray to clean the Electrical end of the Starter.

 

Also:

Where I live there are critters. One of them could have chewed a wire.

I'd also check the wires coming from the starter button/kill switch.

 

Sorry I've been away for so long. Between my computation device deciding that it would no longer wanted to work for me, my job and moving. I haven't been able to be on for quite some time. I replaced the fusebox and fuses. I have power to to all the lights and but the starter still won't turn for me. tomorrow I'm going to chase some wires and hopefully get this thing cranking again. Wish me luck.

 

do these models have a side stand switch? If so check that first. It couild also be a dodgy starter solenoid...

http://www.xjbikes.com/Forums/viewtopic ... relay.html

 

Ok so it is definitely the solenoid. I'm guessing Chacal has these? Super stoked to get this beauty back on the road. Thank you everyone for the help.

 

Yes he does.

Don't rush it and overlook something that could wreck you or the motor in short order.

Rear brakes physically inspected for signs of delamination?

Valves in spec and carbs proper, getting nice tan plugs?

The rear brake is VERY important; if you haven't done it yet you HAVE TO. Read: http://xjbikes.com/Forums/viewtopic/t=15874.html

 

Do a simple test.
Use a battery Charger.

Fold-back the Rubber Hood on the Starter Hot Wire.

Put +12V right to the Starter Post with the Ground Wire on the Starter.

See if it Spins or if you need to douche the Commutator-end.

 

Rear brakes have been inspected. Plugs are a little lean. Next is the valves on my list and I will definitely do as rick said.