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FJ600 No start - no spark - progress

Discussion in 'XJ Technical Chat' started by JPaganel, Jun 24, 2014.

  1. JPaganel

    JPaganel Well-Known Member

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    So, I narrowed down what the issue with the FJ is.

    It is definitely the safety cutout circuit.

    I determined this by disconnecting the black/white stripe wire from the TCI. I did this by taking the terminal out of the connector, it's a safe thing to do with the proper tool (don't go wrecking connectors with big screwdrivers). Mine was a wire tie cut to the size of the slot to press the terminal barb.

    This wire is grounded all the time no matter what, with the stand up or down, with the clutch in or out. With the wire disconnected I have spark. This rules out the expensive part - TCI is OK.

    Now I just need to track down which part of the safety cutout it is. I'm thinking it might be the relay itself, since shorting the kickstand switch wires has no effect. I still need to check the schematic, though.

    Also found out the clutch safety switch is wrecked. However, it's stuck in the position of clutch pulled in.
     
    JPaganel, Jun 24, 2014
    #1
  2. k-moe

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

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    Have you checked it electrically? Just because the switch looks closed, doesn't mean that the contacts are closed, especially since the switch is stuck. Corrosion could be keeping the switch in, but have eaten away the contacts.
     
    k-moe, Jun 24, 2014
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  3. JPaganel

    JPaganel Well-Known Member

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    You know, it could be anything. It's loose and broken.

    I have a slight problem, though. The Clymer manual diagram is not matching what I see on the bike.

    It does not show any b/w wires to TCI and it shows three wires to the kickstand relay where I see four.

    [​IMG]
     
    JPaganel, Jun 24, 2014
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  4. JPaganel

    JPaganel Well-Known Member

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    Of course, it could also be the safety relay...

    Anyway, if anybody out there has a better diagram, I'd be grateful.
     
    JPaganel, Jun 25, 2014
    #4
  5. markie

    markie Member

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    http://xjdiagrams.thundervalleypower.com/
    Here are some XJ 600 schematics - the "1984" Xj600 UK is closest to the FJ600.

    I do have a picture of the Haynes manual FJ600 wiring diagram so if you PM me an email address, I'll send it to you. It does show 4 wires to the sidestand relay!
     
    markie, Jun 26, 2014
    #5
  6. JPaganel

    JPaganel Well-Known Member

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    The diagrams at the link look to be from the same Clymer manual.

    Markie, I PMd you with my email.
     
    JPaganel, Jun 27, 2014
    #6
  7. Hamster

    Hamster Member

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    Hamster, Jun 30, 2014
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