Engine starts.... headlight shuts off, and stays off.

xj650rj, I turn on the ignition, headlight goes on. Hit the starter and the headlight goes off but it stays off. No high or low beam. Everything else works. Any ideas? Is there a test for the headlight relay? Thanks

 

Someone swapped the wires for that relay,headlight should be off when key is on and lights up when engine starts

 

Ok, I'll start checking the wires.
The wiring can't really be mixed up, the connectors are all different. Looks like the wiring is fine.

 

I would suspect a side stand relay (blue marking NC contacts) has been installed in the location of the head light relay (yellow marking NO contacts). And just to be sure you have the correct location the harness should have corresponding colored vinyl tape - blue to blue and yellow to yellow to make sure the relays do not get interchanged.

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

XJ650RJ Seca and XJ750 Euro models:

NOTE: according to the factory XJ650RJ Seca service manual supplement, both the headlight relay and the sidestand relay are under the tank---this is wrong!

It also shows that the ignition cut-off relay is below the TCI?---this is also wrong!

Flasher: near the steering headpipe, on right side frame rail, under the right side ignition coil.
Flasher canceller: under the rear of gas tank.
Starter motor solenoid/relay: on right hand side, attached to and behind the battery box.
Starter/Ignition cut-off relay (no color): on 650RJ and 650 Euro models, located behind self-canceller, under rear of tank (note: the drawing and the description in the service manual is wrong).
Sidestand (kickstand) relay (blue): behind the flasher relay, under the front of the tank.
Headlight relay (yellow): behind the left frame side cover, on the plastic regulator-rectifier mounting plate. (note: the drawing and the description in the service manual is wrong).
Diode block: inside the headlight housing.
Neutral switch: in a hole in the bottom of the crankcase, just "outside" of the oil pan, on the bottom of the engine, up inside a recessed "well".

 

+1. Accidentally swapping those relays (or getting an incorrect replacement) is a fairly common mistake for someone to make.

 

Wow, very good information! Thank you, I'll have a look at those connectors.

 

Here's a pic of what I think is the headlight relay. Seems to be the only connector in that location, and no other relay has a connector that shape.

 

That's the auto cancel unit.

 

The one with the blue zip-ties (aftermarket accessory) holding it on.

pic pilfered from @Busted Knuckles

 

Great! I had an extra relay, swapped it out and now the headlights work when the engine is running. They do come on when you turn the key though, don't know if they're supposed to do that but whatever, as long as they work. Thanks!

 

head light comes on after bike turns over or starts sounds like you still have wrong relay

 

.should not come on just with key you may have the wrong relay still

Identification:
- small metal "cube" relay, inked 3H5-00 on the top face.
- has a yellow (yellow) paint mark on the bottom terminal connector block.
- normally open; has an internal diode.
- plugs into a connector shell which has the following set of wires going to it:

when motor spins voltage goes through the diode block to the +input of coil of the relay, other side of coil is ground.
when contacts close the diode hooked to output side of relay sends plus voltage to the +input of coil of the relay and to headlight, latching the relay on

 

IIRC the 650 Seca has a setup where the headlight is on with the key, shuts off when the starter button is pressed, and comes on again when the engine starts.
It may be the 650 Maxim I'm thinking of though.

 

Checked and yes it's the wrong relay. I'll try and find the right one tomorrow, bike swap meet across the border.
Thanks.

 

The sidestand relay is right behind the self-canceling unit. Before you go searching, make sure that the relays weren't just swapped. Also the correct relays are on Ebay all day long, but you sometimes have to search for small-parts lots to get one for a good price. Chacal should have some too.

 

do you know what relay the wrong relay is?
sidestand or starter cutoff relay?

 

Sorry for the slow response. It looks like the ignition cutoff relay? Not blue or yellow and hard to read the numbers.

 

I see 4H7-0

starter cut off relay
Identification:
- on all models except XJ700 or XJ750-X models:
- small metal (original) or plastic (replacement) "cube" relay, inked 4H7-00, 4H7-01, or 12R-01 on the top face.
- has no colored paint mark on the bottom terminal connector block.
- sometimes labeled or described in manuals and diagrams as a "clutch switch unit", a "neutral safety relay", or an "ignition cut-off" relay.
- normally open; has an internal diode.

as you can see diode is not used to latch relay on the way the headlight relay latches

 

Thanks, there's a local guy who has lots of XJ parts I'll see how much he wants for the correct relay.

 

That is bad news to install the starter cutoff relay in the head light relay position. It's OK until you start the bike, but once started one leg of the generator is feeding 12V through the diode block internal diode and the starter cutoff relay diode to ground. When you get the new correct relay if the head light does not behave normally I would suspect the diode block had been damaged.

 

Good to know, I have a spare diode block as well. Won't run the bike until I get that relay.