Lighting Issue

So, I've been gone for a hot minute, but the FJ600 motor is finally in and running in my 550 frame, with one issue; I have no lights.

Basically, there is no Xj wiring on the bike, aside from the coils and the right hand controls. The head light and tail light are aftermarket pieces that worked with the XJ harness, but I have not been able to get to work with the FJ harness.

Starter button works
Turn indicators work
I'm not running the instrument cluster, but I did plug it in and the oil/neutral switch lights worked. It was light outside, so I'm not sure if the instruments were illuminated.

Only parts of the system that don't seem to be working are the headlight and tail light/brake light.

I will say that I did have to modify the wiring coming from the starter/kill switch as the pinout on the plug is different from the FJ600. This did leave a red/yellow and a black wire, if I'm remembering correctly.

I've been staring at wiring diagrams for a few days now and I can't for the life of me find where the fault may be.


Wiring diagram in question:

http://www.xjrider.com/gallery/albu...1992_Yamaha_XJ600_28U_K_29_Wiring_Diagram.jpg


The only diagrams that I can find are from Euro XJ600's and it looks like the wires that were left over from the right hand controls have something to do with lighting, but the FJ600 did not come with a light switch. I've tried jumping those wires, but it didn't do anything. I have confirmed that the headlight and tail light are working by plugging them into a power source.

At this point, I'm just looking for suggestions on what to look for and if anyone has any experience with issues like this that can point me in the right direction.

Thanks!

 

the black wire is ground for starter switch which also grounds through the handle bars so is is redundant and possibly useless unless your 550 harness had a ground wire in the mating harness connector my 3 550's do not. the red/yellow wire is for the run/kill switch (right hand control)
the 550 has a high low in the left control and has a relay for the headlight
the euro bikes have an on/off switch for the headlight, and a passing light. no head light relay on the euro 600
the switch you are looking at is the on /off switch the headlight high/low is in the lower left corner of the wiring diagram for high/low to right of passing switch. also there is

the 550 uses the relay below which is triggered by a white wire from alternator to turn on head light. recent poster in thread below is using a switch to bypass relay untill he gets a new one.

so you have to find the headlight fuse and the color wire used on the output side of the fuse. which would run to contacts in relay. this is where you would sub in a switch the output of the switch would run to high/low in control. which is the Y. L/B, and G wire in your diagram. the hot wire from relay/switch goes into the switch and is directed to the headlight high or low by throwing the switch yellow and green being the output wires in the euro to head light and the l/b being the input wire.

http://www.xjbikes.com/forums/threads/headlight-issues.43079/#post-574103

 

Thanks for the info. I am running the left hand FJ600 controls, so everything is kosher with the dimmer switch and such.

Red white would be the kill switch. The wires from the right hand controls and the FJ harness are the same color, the pin out in the connector was different. I ended up just soldering a new connector in and running it that way. I need to look at the wiring, but I do believe that my right side controls did have a black wire, which I did connect to the black wire coming off of the harness. I'm doing this off of memory and picture that I have in my phone since I'm at work right now. The starter switch and the Kill switch works. It's just the headlight and tail light that are not working.

Since I'm running the FJ 600 wiring/charging system/ignition, would it be necessary to sub in a relay since they did not come equipped with one, this is under the assumption that it's the same as the XJ600? Everything that was on the FJ wiring harness (relays, diodes, etc.) is still connected to the harness.

As far as looking at the pass switch, according to the wiring harness, it looks like it's a momentary switch that is not required to complete the circuit for the headlight as it's running parallel to the Yellow on the dimmer switch and should have a constant link with the blue wire coming out of the lighting switch.

I have all weekend to play around with it. I still have the XJ harness, so I'll dig around and see if I can swap the headlight relay, if it was equipped with one, and hopefully that will fix the issue.

 

the pass switch is a momentary switch you are correct about it not being needed.
as far as the head light you could just hard wire it , bypassing the need for a relay and it will come on with the key .
my 750 does not have a relay by yamaha design but the headlight is wired into the starter button so when you press in the starter button the headlight goes out.
you can put the relay in you just need a power source to activate the relay the 550 was hooked into the charging system and wiuld turn on the relay when bike started or spun fast enough

 

radio shack would have a diode for you. this would be a substitute for the 550 diode block

 

I messed with it all weekend and I'm still stumped, especially since it's basically a FJ600 in a XJ550 frame at this point with no remaining XJ wiring on it and everything that I took off the 600 is attached to the harness. Next time I get to my dad's house, I'll snag the right hand controls, I just didn't even think about grabbing them and I was rushed to get home. It's still running brilliantly, aside from some carb tuning because I couldn't fit an airbox in the frame.

 

This looks wrong, like it might be for a an XJ600 Diversion (aka Seca II) and not an older 51J XJ600 (like the FJ in US)..

 

Is there a reason you didn't just use the FJ600 right hand control?

If the FJ did not have a headlight relay, then it likely used a set of normally closed contacts combined with the starter switch. You could jumper those wires at the mating connector on the main harness for the right control, which should be an L/B and R/Y as Yamaha seemed to be pretty consistent on this color scheme. The R/Y wire should have 12v when the key is turned on if the combination starter / headlight switch was used on the FJ. Check it with a meter to be sure no fuses are blown or other issues.

The tail light and brake light are a different story. The tail light normally illuminates whenever the key is on and is typically powered by a blue wire directly from the key to enable the "P" feature.

The brake light typically switches 12v to the brake light through a set of parallel (front and rear) switches. Check the connector on the rear brake light switch, there should be 12v on one wire (Br), and when the brake pedal depresses and closes the switch 12v will be applied to the brake light circuit (Y). Same for the front switch, but wire color would change from Br input to G/Y output.

What year is the FJ600 hareness?

 

I'm not running the right hand controls because the bar end on the FJ was seized really bad and I was getting pressure from the wife to pack it up and head home. I do have the controls, they're just at my dad's shop and he lives 4 hours down the road. Next time I'm up there, I will definitely grab them.

I did try and jump the additional wires on the harness, but still no lights.

As far as the brake lights, I'll do some more investigating. Who knows, I could have missed a ground or something somewhere and that could be my whole issue. That being said, I am running a GSXR front end and my ignition has been relocated. Does this need to be grounded on the frame? I never had any issues with the tail light before the motor/wiring swap.

FJ600 was an 86.

 

No, they are not normally grounded to the frame.

Does this match the main harness connector on your FJ; a 10 pin connector?



Also, did the FJ have the two headlights? Either way, if you have the 12V on the R/Y wire check the ground at the H4 connector. Perhaps one of the eyelet terminals(some have one and some two) is not hooked up; usually near the coils using the coil mounting hardware.

 

FJ 600 only had a single headlight. That pin out looks correct except for the brake lever connections. Those are individual bullet connectors that attach to the harness. The control harness is an 8 pin connector. I planned on messing with it tonight, but 98 degree weather is rough to work in lol. I have one eyelet grounded to the coil. I will go back and check to see if there is another that I missed.

 

Or if you have a DMM just check the black wire on the headlight H4 connector and make sure it goes to chassis ground.

I was looking at the FZ print for the two headlights, and I know you said 8 pin, but I am thinking this is the pinout for the FJ:

 

It may very well be a 6 pin. I know that there was only 6 wires coming off of the controls, but for some reason I was thinking there were 2 empty pins in the connector. I may be getting the XJ and the FJ connectors mixed up. In fact, I know I am because the XJ controls are a 6 pin and will plug into the FJ harness, but only has 4 wires.

Thanks for the diagram. This weekend I will probably go in and start to trim the fat from the FJ harness and re-loom it.

 

I'm looking at it and it looks like the Red/Yellow and Blue/black wires are on disconnected when the button is pressed, but usually connected. I'll try to jump those wires when I get home and see if I can get this thing to work.

Thanks again!