Help desperately needed with electrical problems on my 1982 XJ650 Maxim

I am in the process of rebuilding my 1982 650 Maxim after having the frame powder coated. It has been a real headache what with bolts shearing off and getting things put back together in the right order! (failed a couple of times on that one)
It all seemed to be coming together finally but then I started reconnecting the loom via its component connecting blocks (what could go wrong?) Well, where do I start? I have gotten to the stage where its officially driving me mad! I have not reinstated the petrol tank and not started the bike yet! Thought it better to get the electrics sorted first.
I have made sure that there is a good earth connection via the frame by the ignition/rectifier and also by the coils.
Firstly, the main fuse kept blowing when the ignition is switched on via the key. That was traced to the green and brown wired from the alternator to the rectifier. Disconnecting this connector stops the fuse blowing, suggesting a fault somewhere on that bit! (not sure what it is or what to do about it though)
As you can probably tell by now electrics are not my strong suit!
Anyway, that aside, I don't seem to be able to find/trace the other problem, problems, that have manifested.
I have power to the starter. (engine turns) and kill switch works. The horn works, Rear light works, neutral switch is ok. But, I have only managed to get the indicators to work (flash) a couple of times and now get steady lights only. The flasher relay was definitely working yesterday. The same goes for the main headlight and sidelight?
Also, Is there supposed to be a relay for the side stand switch? there is a block connector under the tank space but I don't remember removing one and can't find one in the bits.
I have rebuilt a couple of bikes years ago but not for 25+ so a bit rusty and I am beginning to regret starting this project as it was in very good nick and working perfectly before it was stripped. I wanted to preserve it for the future in an original (or as near to) condition.
I don't know how to use a multimeter properly so not much good at tracing these type of problem.
Any help/suggestions of how I can solve these issues (apart from the obvious one of get a professional in, which I can't afford) would meet with great appreciation.
I know that between you guy's there is a wealth of knowledge and someone will have come across these issues before.
Hoping to hear back in the very near future before I expire through exhaustion!
Many Thanks!
Desperate Ray

 

Hi Ray I am no expert but first of all I had one hell of a time with the wiring on my XJ 900f when I replaced the wiring harness and I did not know how to use a multimeter ehttp://xjbikes.com/forums/threads/how-to-use-a-multimeter-and-read-schematics-and-wiring-diagrams.68164/ither so I know the situation you are in. There is a threat on this forum see K-moe's post above and don't despair there are people on this site who know these bikes inside out. I am still learning about electrical systems but have a look first at the multimeter posts as this is a vital diagnostic tool to help you. Good luck.

 

Many Thanks John for a very speedy reply. I will check out these posts

 

The brown wire from the output of the ignition switch is routed to the Rect/Reg and to the field coil. Since you are disconnecting the two pin connector (Field coil Green / Brown) then it would be highly suspect that the Brown wire has been pinched and shorting to chassis somewhere along the way during the motor install. If you get a handle on how to use the DVM, checking the resistance from the field coil brown wire to chassis would be a good place to start.

It is fairly common for the flasher relay not to work with the bike not running, particularly if the battery is slightly depleted. If you charge the battery to full charge or try it with the charger connected you might find that they are OK.

The headlight is typically controlled with a headlight relay, and will not turn on until the motor (AC generator) spins fast enough to energize the headlight relay. This will never happen if you have the field coil wires disconnected as stated above.

The bike will start and run without the side stand relay. Removing it only defeats a portion of the safety circuit, so perhaps a PO left you that gift. Once you get the other items sorted, then maybe go back to that to restore the safety circuit to its original function.

 

Rooster. Very many thanks for your speedy reply to my dilemma. I have ordered a multi meter and as soon as I can get chance to check out instructions on using/understanding the meter I will hopefully get to grips with some of the issues. Your info will be very useful. Meanwhile I will check for any obvious cable kinks/pinching.
Very much appreciated.
Ray

 

I assume you scrapped paint where the grounds are connected (if applicable)? Using a multimeter, you should have resistance from the ground to another grounding point.

 

Hi V-Max1
Yes I have removed the coating from the earth/ground points. Not sure what resistance the meter should read ( I have a new multimeter being delivered today) but I do get continuity beep on another probe meter. Don't yet know very much about Ohms,Amps but hoping to learn from reading up.
thank you for taking the time to reply to my post.
Ray

 

Hi Ray do you have a manual for your bike I have a Haynes manual for the XJ 900f and the resistance parameters of some components are in there although a factory manual would be better. Also the Haynes manual has a wiring diagram which is very important when you are working on the electrical system.

 

Hi Franz
Yes I have a Haynes manual and I have also obtained a original service manual which shows the parameters for some of the components, and each circuit. So along with my newly acquired multimeter (which I have to learn to use and read) I am hoping that I can find the faults or at least check the circuits one by one. That said, I will probably be back here quite often to ask for more advice! Because even if I get the readings correct, I don't necessarily know what they mean!

 

Great Ray I think once you get used to the multimeter you will find many uses for it as well as the bike, I would never be without a multimeter now. You will get used to interpreting the readings, I was not sure what they meant either at first.

 

How to Use a Multimeter and Read Schematics and Wiring Diagrams.

 

Thanks for the links to using a multimeter. Hopefully they will be a big help.

 

Hi again rooster
Just a quick note to thank you for your help. It was indeed a ground problem but through my own stupidity! This is probably a new one for you! I had the cover of the generator/alternator of for polishing and put it back on with the brushes facing the wrong way! (how dumb do I feel) Hindsight is a wonderful thing and I have learnt from my time consuming error. Everything seems to be working now after some minor blips with the fuel flow. (think it was old petrol or a bit of residue from the tank) Carb cleaner, new plugs and fires up well!
Thanks again for your input. its a big help for old (Retro) bikers like me.