XJ550 Diode Wiring Configuration question?

Hey all, so I've been restoring and reassembling a neglected 550 maxim and have reached a snag at the wiring. PO had cut the plug for the diode block and rewired it with bullet connectors (idk what possessed that idea). I went through all the other plugs, relays, etc with the wiring diagram and they all seem to be wired correctly. When I went hit the starter button once everything was set, the diode pack started smoking and the bike wouldn't turn over.

Ordered a new diode and I made sure I knew which wires were the diodes and which were just resistors. Before I plug it in and smoke another diode block could someone take a pic of their xj550 diode block plug on both ends to verify which wires connect to which? I've read Chacal's ultimate relay and diode guide but it says refer to the service manual for the diode testing, yet I didn't see any diode checks in my service manual. I can follow the starting circuit diagram in the service manual but would appreciate a photo or two of someone's to make sure I did it right. Thanks!

 

i will post photos in the am are you replacing the connectors or going with the bullets

 

front
diode block to Harness
Blue/white--------Blue/white
Black/red ------- Black/red
yellow ------------ Blue/yellow

center wire
white to white
back
diode block to Harness
light blue ----------light blue
green --------------Black/red
white/ green-------White


diode block to left harness right side

 

Awesome, thanks! I got it wired and it started right up today. The new diode has the OEM connector but since the wiring harness side didn't have the connector I just used bullet connectors.

 

I am having an issue with mine too! I wired everything back up as it was when i tore it down. Turned the key to see if turn signals, horns, indicator lights, headlight etc. work. Left front turn signal turns on and stays on, left rear turn signal nothing, right signals blink barely, headlight nothing, removed headlight to see if anything came undone in the bucket to find that my diode block had started to melt. luckily i cut the power before the smoke got out.. the sky blue wire and white wires in the actual block are melting through... any ideas?

 

head light does not come on until bike starts or starter spins fast enough to power relay.

 

Double check the installation of the Relays. They all look similar but are electrically different and can be hooked up incorrectly because the pin configuration is the same. Blue dot (side stand relay) on the relay should match blue vinyl tape on the harness, same for yellow dot (headlight relay) should match yellow vinyl tape. Len has a great resource here to verify wire colors if the vinyl tape is missing as well as the location of the relays.

http://www.xjbikes.com/forums/threads/the-ultimate-relay-switch-sensor-and-diodes-guide.27543/

 

i think you should get your meter out and test that again. this is why i tell people not to test with a battery, use your charger instead

 

i never unhooked the relays, i just kept them in their spots on the wiring harness

how do you mean. I have a trickle charger, can i just hook this up in place of the battery to test the circuits?

electrics, like every other step of this rebuild process, is brand new to me.. i thanks you guys once again for the help and suggestions..


thats my diode block.. when i discovered it had started to melt, i also disocvered that the little rubber cover had fallen off.. cold this have something to do with it? i know rubber is an insulator

 

well all the tenders are different but try putting it in, in place of the battery. check the headlight first, if you see a little glow, your good. if not the charger doesn't have the beans. now unplug the headlight, it will take most of the power you need for other tests. the starter relay should click, the turn signals should glow, brake light, tail light. if something doesn't work you can check it without hurting anything