'82 XJ650 Maxim Electrical Trouble

Hey guys I just recently bought my first motorcycle to fix up and ride and I am running into some tough electrical problems, if you could help out it would be very much appreciated!!
The bike was cranking, but it wouldn't start (good spark, good carbs/ fuel, and good compression). I turned to the battery and it turned out to be bad. I got a new one, but as soon as I started cranking it, it wouldnt stop cranking even after i took the key out and the starter, its wires, and the battery all got hot. I had to disconnect the battery and let it cool down, i came back a couple hours later and decided to hook the battery back up, but the second i completed the circuit the bike started cranking, so i disconnected again (key is still out of bike). I used a voltmeter to check the solenoid and it is perfectly fine, so i tested the starter with cables and the battery and it worked perfect. I guess i was convinced the problem was in the starter so i pulled it apart then cleaned up the commutator and such and then put it back together, since then, it spins, but really slow and it gets very hot. Should I buy a new starter motor or just buy a rebuild kit that has new brushes? Also, the left turn signal, when activated, does not cancel, it just stays solid until i turn it off. The right works fine and they both use the same relay so should i replace the control switch? I also have a wire that hangs down next to my battery compartment and I have no idea where it should go. It has a circular boot on the end and it seems to be a cap of some sort, but it has been hanging for a long time, as it is rusty and worn and there is nowhere for it to go, does anyone know what this is??

 

So, you have the key out of the ignition and it cranks? I'd start here http://www.xj4ever.com/clean and lube the ignition switch.pdf

The turn signal sounds like a burnt out light. Does both the front AND back light up?

smarter people will be along soon to add useful insight

 

The wire by the battery compartment is most likely the old battery monitor wire. It used to hang in *one* of the cells and would tell you if the battery voltage as low. I think most people bypass it these days. (Bypass by giving it constant 12V)

The starter acting as it is could be a few things, they're all maintenance items. Could be the starter relay sticking, or the starter button sticking, you're doing the right thing by ohming out circuits with the battery disconnected to see what's "connected" and what's not.

The others will be by with more advice

 

Ben,

Welcome to the forum! You have jumped right in, we like to see that.
With these older bikes it is really best to go through all the wire connectors from front to back. Take your time and get some little brushes, picks and some dietetic grease.

Disconnect the battery, start on one end of the bike and make your way to the other end. Any connections need to come apart and do it carefully as these wires are old and I am guessing you will find some issues with a few. The yrs of being in the elements have created corrosion to form on the connectors and maybe even caused opens and shorts in the wiring.

Once you have done this you can start to trouble shoot the rest of the issues. You might fix and or find electrical issues along the way, fixing them might save some issues you are having.

Best of luck, congrads on the bike and keep us updated with your progress.

If you have not taken a Motorcycle Safety Foundation class yet, please sign up for one. MSF https://www.msf-usa.org/
That is the link you can find one in your area.

 

82 Maxim does not have this feature.

It sounds to me like the solenoid got hot while you were cranking and the internals fused up therefore completing the circuit. I've seen this happen on older worn out/dirty solenoids that heat up too much while cranking the starter. See if you have continuity between the two large posts with nothing hooked to it. If so it is stuck "on".

 

That happens all the time on golf carts too, but typically it's when they get an under-rated cheap solenoid and end up welding the contacts from the motor draw.

If the starter is turning really slow and getting hot then you have something bound up. Did you put the brushes back in their original location and orientation? Are you sure the rotor seated all the way into the end bushing? You should have been able to easily spin the rotor before you put the planetary gears back on.

 

q

 

Ive already tested the solenoid and it is good. the posts do not allow continuity until a current is applied and the posts are connnected.

 

Okay then, so with the large posts hooked up only the starter should not spin, is that the case? I would suspect when you hook the blue/white and red/white wires back up the starter will crank.

If so we need to troubleshoot that circuit.

Blue/white should only show ground when the starter button is pressed. If it shows ground all the time then you should check that the start button and associated wiring is okay. If that is okay, unplug the diode pack in the headlight and check again. If that wire no longer shows ground you have an issue with the diode pack or associated wiring.

Red/white should only show 12V+ if the bike is in the proper state to be started (i.e. in neutral with stand down, in gear with stand up and clutch pulled, etc.). Try leaving your kill switch off and see if it will crank. If not and will crank when you turn the kill switch to run, then the "hot" side is probably okay and you should look at the ground side. The FSM has excellent procedures for testing them.

This all assumes that you have a stock harness and correct solenoid etc.

 

UPDATE:
I have fixed the starter motor (when I was putting it back together originally I had screwed the positive terminal bolt in so that the metal flap was touching the brush plate) it spins perfectly now. I have already tested the starter solenoid, the battery's ground wire, and the positive and ground wires to the starter solenoid... all working fine. However, I suspect that I will still have the problem where whenever I stop cranking the engine, it will keep cranking and I will have to disconnect the battery to stop it. I think I need to check the ignition switch and possibly get a new control assembly for the handlebar, but I am not sure how I should go about diagnosing exactly where the problem lies. If anyone knows how I can check the ignition switch and the wires in the circuit, please let me know, it would be greatly appreciated! I also plan on testing the stator but I am waiting on the manual I ordered for the bike to arrive so I can have the correct readings to test for. I also still have not found where that hanging wire by the battery case I mentioned earlier in the thread goes or what it is. I have not connected the battery to the bike yet, but I assume that the left blinkers will still be malfunctioning. I am brand new to motorcycles and I am learning as I go, any help would be greatly appreciated, thanks!!

 

If you’ve tested the positive and ground wires that go to the solenoid coil and they are working fine, then you don’t need to check the ignition switch. If I’m understanding you correctly, the starter does not spin when you hook the battery up but once you press the starter button it spins but will not stop spinning when you release the button?

Have a picture of the hanging wire? That will help a lot.

We can deal with linker later once you get this sorted.

 

One more note, leave the wire going to the starter disconnected from the solenoid while you troubleshoot. That will save unnecessary spinning of the motor. You will feel and hear the audible click of the solenoid. Should click firmly when you press start and release when you release.

 

UPDATE:
I disconnected the same colored wires in the headlight mount that run to the solenoid and it was pretty dusty so I blew it off and plugged it back in and connected everything back together, and I no longer have the issue of the bike cranking the moment I connect the battery... an improvement. When I insert the key, the lights and sensors work, but nothing is happening when I press the starter button, not even the solenoid clicking. Once again, I know that the starter motor, solenoid, and all the wires between the battery, solenoid, starter, and ground are good. I uploaded the pictures of that plug to my computer, but I couldn't get them in my post.

 

You need one more post before you can have links or photos.