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Need some help!

Discussion in 'XJ Technical Chat' started by Johnny And June, Aug 30, 2015.

  1. Johnny And June

    Johnny And June Member

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    So I just bought my first bike. It's a 1981 XJ550 Maxim. It's a beautiful bike, but she's not starting or running. I've recently just bought a brand new battery and installed it (I also have the Clymer manual, so I've been tinkering around with some stuff.) The bike won't do anything. The electrical won't turn on, no lights, nothing. The guy I bought it from said that it was running a little over a month ago, but it stopped recently. When he tried to start the bike there was a clicking sound (he said something about the safety switches?) Could yall maybe lend a brother some insight into what I should be trying? I'm semi-mechanically inclined so I can do some maintenance myself.
     
  2. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    Check the fuse block if it is original , replace it because they were prone to the fuse clips breaking and burning up. Chacal has what you need to upgrade your fuse block including wire harness pigtails.
     
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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  4. pygmy_goat_

    pygmy_goat_ Member

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    The fuse box will probably need to be upgraded as you guys say...but OP did ask for some suggestions on where to start to figure out why no electrical.

    I'd suggest seeing if any fuses are burnt out, or if there is anything actually wrong with the fusebox. I don't have one of these bikes, but as they said its apparently a common source of problems on them.

    If there are any clicks at all, then there is power somewhere, so I am not sure I understand what you are saying, Johnny and June. Does it click now, or did it click at the moment it died?

    Could easily be a fuse, the fusebox, or a safety switch (sidestand, clutch, neutral). Need a bit more info.
     
  5. quebecois59

    quebecois59 Well-Known Member

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    The way I understand it, the previous owner heard a click the last time he tried to start it, but Johnny and June says it hasn't even clicked once since he bought it. The circuit is open somewhere, if the fusebox is original, it is a good place to start checking.
     
  6. XJ550H

    XJ550H Well-Known Member Premium Member

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    Johnny and June open this link
    http://frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html
    you battery is new and fully charged.
    test your fuse box for voltage pull the fuses and ohm them
    voltage comes from battery to main fuse 20 amp check for voltage on both s ides of the fuse.
    when you turn on the key ignition switch, voltage from main fuse goes to the key switch then goes back to the 3 other fuses. it also goes to the tail light and lic plate light directly from key.
    if you get no voltage reading on both sides of main fuse clean your ground wire on battery and its connection to the frame. clean the positive wire as well.
    if you have voltage at main fuse in and out check connector at key ignition switch for voltage at red wire
    if you have voltage at red wire check for voltage at blue wire and brown wire.
    no voltage clean the connectors contacts, retest still no voltage
    your key ignition switch will may need cleaning or replacement
    on the wiring diagram if you hover over the black bar at the ignition switch you will see it is a 3 position connector blue, brown and red wires red is from main fuse to key blue goes back to tail lights and lic plate light ,
    brown goes to fuse box for distribution
     
  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    if you suspect the key switch disconnect the connector turn key to on and test for continuity from red wire to blue wire , then red to brown wire.
    no continuity how to clean your switch
    http://www.xj4ever.com/clean and lube the ignition switch.pdf


    check you tail light bulbs to see if they are good
    understand you will be spending money on tools its time to set a budget.
    you can get a meter for 9 to 20 $
    you can get a test light for 8$
    pick up a few test leads (wire with aligator clips on both ends)
    get an inline fuse holder blade type and a 10 and 20 amp fuse for it
    also want a few aligator clips to attach to fuse holder.

    best way to test your grounds is to clip your meter or test light to the positive clip in battery, then touch your motor with the probe see if you have light then test the frame in the same manor in an unpainted spot or at a bolt that goes into the frame
    get a spray can of electrical cleaner and fine sand paper wet dry type of crocus cloth if you can find a sheet it is for cleaning connectors. aslo get some dielectric grease you use this to protect connections you have cleaned and for your light bulbs sockets.

    fuse clip lead.JPG
    you can clip this across your fuse clips to test your fuse clips, use a 10 amp fuse.
    clip across main fuse clips, turn on key ,then test for voltage on other fuses in and out
     
    Last edited: Aug 31, 2015
  8. Johnny And June

    Johnny And June Member

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    Thanks for the replies guys. I ended up ordering an aftermarket fuse box from chacal to install. I've got a friend who is a little bit more technically inclined than I am to help with all the wiring and such.
     

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