Maxim x xj700x no power to fan fuse

Hello guys,

My fan stopped working my XJ700X. Everything else electronically works as it on the bike. Here's what I've done so far:

1. Jumped fan directly to battery, fan kicked on
2. Jumped the thermoswitch, fan did not kick on. Found no voltage coming to thermoswitch
3. Checked fuse. Looked fine, replaced anyway.
4. Found no voltage between ground and fuse (checked both sides of fuse). All other fuses have 12v as they should.
5. Checked continuity from fuse to both ground and positive terminal on battery. Nothing on either. Did this for all other fuses and they as expected had continuity to positive terminal
6. Found 6 pin brown connector on the neck of the bike, which contains the red wire that supplies power to the fan fuse. Checked continuity between connector and fuse. Connector has continuity to fuse, but not to positive battery terminal. No continuity to ground.

I'm doing all these checks with the bike keyed on. Here's where it gets weird. At some point in my troubleshooting, I gained power back to the fan. Got 12v to fuse, 12v to the brown connector on neck of bike, and 12v to the red thermoswitch connector. So I started the bike up, running it to see if the fan would kick on. I continuously monitored voltage at the fuse while running the bike, everything was looking good until it came time for the fan to actually kick on. Voltage dropped back to 0. I then shut the bike off cause it was starting to overheat. I checked voltage again, 0V. I then checked voltage from battery positive terminal To the fuse, heard a click and the fan kicked on for a moment and shut off.

This almost seems like a relay issue to me, but there are no relays on the fan circuit prior to the fuse. I'm inclined to believe I have a broken wire somewhere, since I don't have continuity to ground or the positive terminal, and it seems I intermittently am getting 12V to the fan fuse. Before I start digging into the main harness, want to see if anyone else here has ideas.

According to the wiring diagram, the fan power is a pretty simple run from the battery. What's weird though about looking at the diagram, is the fan power doesn't appear to be on keyed power, but it definitely is since if you shut the key off the fan does shut off with it. Maybe something is missing from the diagram?

If anyone wants pictures, let me know. I have the wiring diagram as well. Thanks for the help, scratching my head here.

 

Have you checked the wire and contacts in the back of the ignition switch?

 

unless this wiring diagram is wrong fan is not key switched and fan should run after bike is shut off just like some cars do to cool the motor.
runs directly off of reg when bike is running and off of main fuse to battery.

 

Yes, I agree according to that diagram it should not run off of keyed power. That's the same diagram as my service manual.


I checked the two red wires after the brown connector before they go up into the fuse block, and they have continuity regardless of if the key is on or off. But I remember fairly clearly that it was switched with key power, because sometimes after getting in from a ride on a hot day I would key off, then key back on to let the fan run until the bike cooled down.

Checked the two red/wires coming off the ignition switch, no issues there it seems. Continuity when switch is on, no continuity when switch is off

 

do you have continuity to the main fuse to fan fuse? 49 to 4

what happens is battery supplies key when bike is started brown wire feeds from regulator while battery charges through main fuse.

sounds like you need to check connectors at key main fuse and regulator..

we need an x rider to comfirm fan operation

 

I do not have continuity from the main fuse to the fan fuse. I do have continuity from the main fuse to all other fuses.

Yeah, it's been since last season since I've rode with the fan working properly, possible I'm misremembering.

Also interesting, this red wire behind the headlight doesn't look factory, it has a butt splice wrapped in electrical tape. It goes up into into the key switch area. Above it is the brown connector which contains the two solid red wires for the fan, I believe it's suppose to connect 4 to 49.

 

main fuse is always live it feeds the ignition key then goes to all other fuses via the brown wire.
the red wire to fan fuse may be at regulator connector or main fuse output or up at mainharness to ignition key connector .

you want to make sure the output of main fuse has continuity to voltage regulator red wire or you may be charging battery with brown wire through the ignition switch

 

I think you are onto something...

Plug right off rectifier, this might actually explain some low system voltage issues I used to encounter when the fan actually worked

 

Update on this old post. I did end up replacing the plug coming from the rectifier, recrimped all the wires in there as well so connections are good. Still don't have power to the fan.. 0 volts at the fan fuse. Back at looking for a poor connection somewhere from the stator plug to the neck of the bike.

 

Sorry for double posting.

Started peeling away the loom for the harness, and found the red wire for the fan power that is supposed to go directly to the stator actually loops back and connects to the brown switched power. In the loop back the wires had broken in the insulation.

Soldered up the wires in a way so it no longer has to make a 180 degree turn, fan is running great now.