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Needing Help Undoing Previous Owners Mistakes

Discussion in 'XJ Technical Chat' started by Matt Day, Jun 20, 2021.

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  1. Matt Day

    Matt Day New Member

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    So I picked up a good running 82 xj750 maxim, it was a bit rough looking so I decided to take it down to the bare frame and build it back up (just a cosmetic freshen up) skipping passed all the cosmetic clean up I’m now at the point that I’m ready to fire the bike up and ride it. Here’s where the issue starts.

    The previous owner for some reason unplugged the top harness on the TCI and made a spaghetti mess of bypass wiring. Problem being I’m apparently too ignorant to have take note as to where these connected to. When reassembling the bike I of course put all the wiring back into their factory locations. Now I have no spark.

    Another odd ball thing to note is. Before disassembling the bike the kill switch on the bars did not work. You had to turn the key off to kill the bike. Now the kill switch does work.

    The time line of running riding bike to now is about two weeks. I have already tested the pick up coils and coils which are within spec. The battery is good and I am getting good power to everything that should have power during a starting condition.

    my main question is. What could he have bypassed that would have need this big mess of wires to make it run?
     

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  2. Minimutly

    Minimutly Well-Known Member

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    Oh dear, the dreaded PO strikes again.
    You need a wiring diagram. All XJs have a safety circuit of sorts, the exact model and country of origin plays a big part.
     
    Jetfixer likes this.
  3. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    From here it looks like this:
    -The bike has pods, so the air box is missing
    -the airbox is missing so the mounting spot for the fuse box is no longer there.
    - the fuse box appears to be replaced with either inline fuses , blade fuses, or direct wire.

    my question is...... has the kickstand switch been disconnected? If so, you need to either reconnect it or make a jumper for the terminals in the wiring harness so the bike THINKS that the kickstand is up. Better to have a working kickstand switch though......
     
  4. Minimutly

    Minimutly Well-Known Member

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    Is the safety relay there?
     
  5. Matt Day

    Matt Day New Member

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    All of the factory relays and safety equipment is in place still. The kick stand switch is also hooked up yes.
     
  6. Matt Day

    Matt Day New Member

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    At this point I’m ready to try and rewire the bike from scratch does anyone here have any experience doing this?
     
  7. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    I would Caution against doing that.......more methodical trouble-shooting is what is needed.
    Now, don’t take this as a smart-aleck question:
    How do you know there’s no spark?

    Other questions:
    -If you had it running before, and now you don’t.....wouldn’t that be something YOU did? Gotta find it.

    -if the bike isn’t firing, how do you know the kill switch works?
     
  8. Minimutly

    Minimutly Well-Known Member

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    Same as @hogfiddles , don't do it. Get a manual with diagram, verify which version you have and check through on your bike. Don't want to do that? Well you certainly don't want to be rewiring then..
     
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  9. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Since it was a good running bike when you got it, and after you tore it apart and put it back together, it’s something YOU did..... so you just have to figure out what you hooked up wrong— or didn’t hook up yet.
     
  10. Franz

    Franz Well-Known Member

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    And taking pictures helps putting wiring back together but wiring diagram is essential.
     
  11. Matt Day

    Matt Day New Member

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    I found out what he must have had bypassed. I pulled the harness and found several burnt sections of wire that had been clipped off!
    I’m thinking now of going the Motogadget m unit. Has anyone here used that as a wiring option ?
     
  12. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Get a good used harness. About two hours of work and you'll be riding again.
     
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  13. Matt Day

    Matt Day New Member

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    Thanks for all the advice. I’m a first time poster here. I’m glad to see such a supportive community.
     
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  14. Minimutly

    Minimutly Well-Known Member

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    Good advice here - summer is for riding. Motogadget will take a while to sort, and you'll still need a chunk of Yamaha loom, or make your own
     
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  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    I happen to have a harness for an 82 maxim start a conversation with me. I have an air box too.
     
  16. Matt Day

    Matt Day New Member

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    I actually just had my moto gadget delivered today. We’re gonna see how that goes first
     
  17. XJ550H

    XJ550H Well-Known Member Premium Member

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    those are nice
     
  18. Timbox

    Timbox Well-Known Member

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  19. jayrodoh

    jayrodoh YimYam Premium Member

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  20. Timbox

    Timbox Well-Known Member

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    Thanks @jayrodoh , I was wondering if that cheep box had the ckt breakers in it like the motogadget does.
     

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