1982 xj750 maxim no start after wiring in neutral light

My bike came without the stock cluster and I wanted to add a better one. After many hours of wiring I got the turn signals, tach and speedo to work. The bike ran with the wiring I did. I forgot to wire the neutral light until the end and after searching I found a wire that I believe to be the neutral signal wire. I connected the cluster wire to the believed neutral wire and the light came on I shifted gears and the light turns off as it should.

When I attempted to start the bike, nothing at all. The headlight and tail light are on but the bike work crank. Not even a click.

Now the neutral light will not turn on. I disconnected the wire and still no life.

Could I have connected the wrong wires together? It burnt out the neutral switch?


This is the sky blue wire I believe to be the neutral

I've tried push starting it and a couple cylinders fire but i don't push it fast enough to fully start it

Any help would be appreciated

 

do you still have the safety relay?

 

Where would that be located on the bike?

 

mine is in a box under the bench, i don't remember where it was

 

From looking around on my bike I don't seem to have the fuze box nor any relays. I've provided a photos of what I can see

 

I have done some more touble shooting, bypassing the starter solenoid cranks the starter with no start. When I press the start button it turns off the head lights, like normal. So I can assume the button still works.

My bike normally doesn't start in gear, it would only start in neutral and could start without me pulling the clutch in. Could something have fried when I connected the neutral light wire causing my bike to think it's always in gear making it unable to start?

One to many stalls while learning cause it to not start in gear I believe

 

If you pull the clutch lever, does the start switch run the starter then?

The light blue wire is the neutral switch signal, and it normally runs to the starter cut off relay, the indicator lamp, and the diode block. The switch grounds the light blue wire when in neutral.

Maybe, if the switch is not making great contact, the extra current from your neutral lamp is pulling the high side of the switch up too high. If you jumper the light blue wire to ground (with the bike in neutral), does your starter crank then?

 

The starter does not run at all with the start button even with the clutch pulled. The clutch switch also isn't fully seated seated because the clips broke. It's popped out a bit. I've tried baypassing the switch as well and nothing still.

As for the other stuff in you reply, I will have to continue tommorow morning. It's too dark outside currently.

 

YES IT RUNS, it's started right up perfect after grounding the sky blue wire to the engine. Now that I know the problem how can I wire up a neutral indicator properly?

 

If that corrected it, then I think the neutral switch is bad... not making strong enough contact in neutral.

 

Is there any ways I can fix the neutral switch or would it just have to be replaced? A neutral light would be really useful

 

SQLGUY, I've looked at another thread on the neutral switch. someone said putting seafoam in the crank case and letting it run for a bit while running through the gears made his neutral switch start working. Would you recommend that?

Would I add it through my normal oil fill or is there another place that would be better? I'm due for an oil change anyways.

 

If you are due for an oil change it's the perfect time to try some seafoam. I'd add a couple ounces and run it a few miles to get it up to temperature and then change the oil. It might work. You really haven't got a lot to lose. It won't hurt anything.

 

I would just replace the switch.

 

One more question. The bike would sometimes not start with the sky blue wire grounded. Is there any other reason it would not start, when it would start other times?

Also I've noticed when I would connect the ground I would hear a click somewhere on the bike and it would start after the click. When I wouldn't hear a click it wouldn't start

 

The sky blue wire is the neutral switch wire for the safety relay (which is the click that you were hearing) It also iluminates the neutral light. It should be grounded when the transmission is in neutral, and only when the transmission is in neutral. Otherwise you can start the bike when in gear without using the clutch, and end up on your backside.

When the safety relay is not energized power is cut to the TCI, preventing spark.
The safety relay should click when you turn on the ignition.

 

Thank you for the wonderful explantation.

Let's say the neutral switch was not faulty, like it was before me wiring the light on. What else, relating to that system, could cause the bike not to crank and start? I just want to figure out all my possible options from I take my exhaust off to replace my neutral switch.

 

To start the transmission has to either
1. be in neutral
or
2. be in gear with the clutch disengaged (pulled in).

If you suspect the neutral switch to be faulty you can temporarily ground the sky blue wire.

If you suspect the clutch switch you can unplug it and use a bit of wire to jump the terminals.


The only other safety device is the sidestand switch. If it is sticky it will behave as if you are trying to pull away with the sidestand down, and cut power from the TCI. This can be tested by pulling the sidestand realy as mentioned above. The fix is to use contact cleaner on te switch plunger to clean it out, and follow up with a dry-film lubricant. Though it sounds like this is not the issue in your case.