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brake lights quit working now blown ignition fuse

Discussion in 'XJ Technical Chat' started by XJrider650, Oct 1, 2016.

  1. XJrider650

    XJrider650 New Member

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    Hello all,
    New to the forum so hello from Florida! I aquired a 1982 XJ650R Seca about 6 months ago and have slowly been turning it into a cafe bike. Today I noticed that my breaker lights quit working..taillights work but no brake lights. While trying to sort out this issue it began blowing the main ignition fuse when the key is turned to the on position. Whether the kill switch is in the run or off position doesn't matter, as soon as the key is switched on it blows the ignition fuse. Inspected all wiring including the connections n the headlamp bucket and cant find any bare wires or anything of the sort. Is it possible this is a bad ignitor box? Any help will be greatly appreciated as this bike is my main mode of transportation. Also I searched the forum posts and could not find anything the fit my exact situation. Anyone have any ideas? Thanks in advance!
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    tail light runs off of the main fuse
    brake lights off of another fuse.
    check your fuses.
    have you checked the bulbs?
    next is to check brake light switches

    have you upgraded to a blade fuse box?

    main fuse gets power from battery then to key where it sends it back to the remaining fuses the wire branches out to the others

    do you have an atri cluster?
    you could have a short in there

    if you read this link it will have a link to your wiring diagram
    The Information Overload Hour

    TCI box unplug it then try,

    check your recent work like what wires have you unplugged and reconnected
     
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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  4. hogfiddles

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

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    Sounds like a pinched and bared wire under the seat
     
  5. XJrider650

    XJrider650 New Member

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    Ok so quick update...I do have an upgraded fuse box..blade fuses..I do have a cluster and no I dont have a repair manual lol I know I should really invest in one. I have since traced the main ignition wire up to the ignition switch and there are no bare spots of any kind..I tested the wire all the way up to the switch and the wire is fine. Would this mean that my ignition switch has crapped out or is there something else that would cause that main circuit to surge?
     
  6. hogfiddles

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

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    You still have a short somewhere.... Check inside the headlight bucket. Often wires can get bare there, too. If nothing there, then pull the switch off and start testing that.
    BUT
    before you go through all that double check to male sure you didn't accidentally hook up any wires wrong-- like wiring a ground wire to a hot lead....wouldn't be the first time I've seen that
     
  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    check your inbox i sent you a message you will find a link to 650/750 manual that I uploaded

    it will help
     
  8. XJ550H

    XJ550H Well-Known Member Premium Member

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    pull out all but the main fuse this should isolate the short to what the main fuse controls

    in a nut shell battery feeds main fuse 1 position connector it may be hooked to solenoid or battery, then main fuse feeds ignition switch then there are 2 wires one which feeds tail lights and one that feeds other 3 fuses in the fuse box that wire goes to fuses splits into 3 wires then connect to fuses. same wire to fuses also connects to the alternator and voltage regulator

    disconnect connectors to alt it is a 2 position connector and regulator 8 position connector then ohm out the alt and v regulator, see if main still blows
    if no other fuses are blowing your problem should be with the main fuse circuit

    check tail light wire at the metal clip on the fender for damage
     
    Last edited: Oct 3, 2016
  9. XJrider650

    XJrider650 New Member

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    I already pulled the switch off to check it wasn't all that bad actually but I didn't see any issues in it except the main hot has a slight amount of rust on the soldering point, not sure if its enough to cause a problem though. I'll double check ALL the wires in the headlight bucket tomorrow as my lighting in my garage sucks horribly lol tomorrow i will follow up on these leads and update. Thanks everyone for the fast responses..I can tell this is a great forum already lol and also XJ550 thanks for that manual. As im sure it will come in very handy lol
     

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