86 xj700x 9 wire turn signal switch starter relay showed up problem

Replaced the main wiring harness on my 85 xj700x. Had to get a relay for the turn signal starter relay. Installed it. I have a headlight now but when I hit the start button the starter doesn't try to start up the headlight shuts off and the oil light comes on

 

Headlight off and oil light on is a normal condition when pressing the start button.

Starter not spinning can be many issues.

Starter switch - must provide a ground path to engage the solenoid, yours is likely OK if the oil light is illuminating.

Starter cutoff relay contacts are not closed because safety circuit is deployed disabling the starter. You must have a working neutral switch OR a working clutch AND side stand switch. Either condition should enable the starter cutoff relay and close the contacts to enable the starter.

Starter cutoff relay is defective

Starter solenoid is connected incorrectly - the battery positive must be connected to the post on the solenoid that contains the metal terminal.

Caution on two test below - bike in neutral and on center stand:

Starter solenoid is defective - has a single small lead (L/W) that is routed through the closed contacts in the starter cutoff relay and then to ground through the starter button. Test by grounding L/W lead and solenoid should clunk and starter should spin.

Starter is defective - Test by shorting two large terminals on starter solenoid with old screwdriver, starter should spin.

Wiring is defective

 

The headlight turns on when I turn key to on position when I press start button headlight goes off oil light comes on

 

I keep on having to tap the starter solenoid. For power to go to head light and cluster. I jumped the terminals and starter kicked over. So would the solenoid be bad

 

Normal, the starter switch has a set of normally closed contacts for the headlight. When you press the switch the contacts open turning the headlight off

Also normal for the oil light to come on when the start button is depressed.

Not sure how to interpret that statement.

First, make sure the solenoid is wired correctly as mentioned above - the battery plus connects to the solenoid post with the metal terminal




If it is wired correctly try grounding the smaller L/W wire, the solenoid should clunk and the starter should spin.

If that works likely safety circuit deployed as mentioned above.

 

When I ground the l/w wire the starter kicks over

 

So the solenoid is OK. Time to troubleshoot the safety circuit.

Does the neutral light illuminate? Is the diode block installed? The diode block is needed for the starter cutoff relay to be engaged when in neutral.

Do you have the clutch safety switch installed? If so, try pulling in the clutch and put the sides stand up and see if the starter will engage when you push the start button.

Remember, to engage the starter cutoff relay you must have a working neutral switch OR a working clutch AND side stand switch.

 

also try cleaning the starter button open up the control spray with electric cleaner then apply dielectric grease

 

Had to order a clutch AND side stand switch. Don't see wire hook up for the neutral switch. But I have ground the neutral switch wires of the harness and it's starting up when I hit the start button

 

Great, you have made progress. Remember what got you to this point, persistence and determination! From now on slow and steady and each time to make a change to the electrical system do a check to make sure you are going forward and not back.

 

I see neutral switch online for sale but I don't see where the wires hook up

 

I am not sure exactly where it is located on the X model, but usually on the underside of the motor near the left frame rail. Should look something like this:

Hopefully, yours is still in working order and you just need to get the wire connected at the screw.



This link has a very nice photo of the location on the 650, and I think it will be very similar on the X.

http://www.xjbikes.com/forums/threads/xj650-neutral-switch-location.75495/

 

What is the black wire purple strip for that's with the light blue wire that goes to the neutral switch

 

Is that hole where the neutral safety switch should be??

 

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".

photos of location of switch outside and inside of case left side of motor

 

Ok thank you I got the gas tank and carbs thrown back on this morning it fired up But can't get it to drop below 6k

 

I figured out my idle problem

 

what was your idle problem??

 

I would fire it up and couldn't get it to drop below 6k. I backed out idle screw and still no change. I notice that the plastic throttle screw on the cable up by the throttle was backed out so I screwed it in towards the bike and the idle went down.

 

Good catch...