No spark-where to start looking SOLVED

I have an xj550 that just got put back together. All relays and switches have been put back in but the bike doesn't seem to be getting spark. I have had battery on trickle for 2 days and still nothing. I also pulled out the two relays under tank (one at a time) to see if its the stand safety switch but still nothing....any ideas?

Dont know if it makes a differance but I also have these two wires that i cant seem to find a home for. They reside under the seat area connected to the main harness. one is sky blue (almost teal) and the other is black with white chaser.

 

Re: No spark-where to start looking

Light blue is used for the neutral switch, which is also part of the safety circuit. Black/White is, on some of the bikes, at least, the TCI cutout from the safety circuit; though disconnecting it normally bypasses it.

Troubleshooting guide is here: http://xjbikes.com/Forums/viewtopic/p=274100.html

 

Re: No spark-where to start looking

where are the male and female wires to this neutral switch. i dont think i just threw it out lol

 

Re: No spark-where to start looking

also, i ordered a new fuse block. found out that mine is loose and i will be getting my battery load tested after class

on the factory fuse block 1 + 2 are loose/disconnected

anyone know what they do?

i know #1 is for starter because if i dont hold it on the handlebar starter button wont work. u can actually see its not connected above lol

so....

1) starter
2) ?
3) ?
4) ?

 

Re: No spark-where to start looking

I can't tell you from here where your neutral switch wandered off to but shouldn't you be able to just plug those together to spoof it.

 

Re: No spark-where to start looking

Anyone know the cold cracking amps of a maxim 550 battery

 

Re: No spark-where to start looking

Probably 113

 

Re: No spark-where to start looking

I got it tested at autozone and it checked out. The thing id though is that he checked it at 110 because his meter couldn't single digits. Should I check it at 115 cca?

 

Re: No spark-where to start looking

I doubt that the battery is the problem. How far did you get in the troubleshooting guide?

 

Re: No spark-where to start looking

Update.
I didn't believe the autozone test....just something wasn't right. So I brought it to work and used our battery tester and sure enough it failed. Cca set at 110 and 115 it failed both times only pulling 70 cca.

Its holds a charge but has no load capability.

Followed through procedure and have good volts at tci before cranking but not after. This is why I thought battery

 

Re: No spark-where to start looking

How far is the voltage falling when cranking?

Do you have a good battery to try? Even a car battery (separate, or with the car's engine not running) and jumper cables should allow you to determine whether the battery is the problem.

 

Re: No spark-where to start looking

Inspect the Alternator Brushes.
10mm or less = replace.

Inspect Alternator Rotor
Look for scorching on the Rotor's Brush Orbit Paths: Remove with Pumice-tpye Typewriter Eraser.

Test Alternator Output.
+14.2V DC at Battery with Engine at 2000rpm's.

Replace Fuse Panel.
Original can look fine and still be the source of a dead circuit.

 

Re: No spark-where to start looking

His bike's not running yet. He's looking at the battery as possibly part of the cause.

If it's only testing 70CCA it's not gonna fire up a 550, guaranteed. I agree a new battery would help.

Alysiak, I answered in your other thread about the battery.

 

Re: No spark-where to start looking

thank you fitz.

 

Re: No spark-where to start looking (SOLVED!)

well i would like to tell everyone that the factory harness has bad information. When i had these two wires left after putting the bike together, it was unclear as to where they went. According to the harness the sky blue wire is the neutral switch....got it, but at the neutral switch the wire is blue with yellow tracer. so this left me with no wire to attach to. I then looked and looked and looked and sure enough i dug up a picture from the dissassembly and it wasn't clear at first but it goes to the tci.



if you look in this picture you can see on the left side where it clips into the last clip on the right tci plug. The other black wire goes into the wire i thought went directly to tci. O well, i cant be mad now and i hope this helps future xjers!!!

tip: TAKE PICTURES you never know when they could help you out!

p.s: Thanks fitz

 

Re: No spark-where to start looking

Interesting. I guess that's a difference between the 550's and the 650/750's. I know for sure my factory harness has light blue for the neutral switch, and has no light blue wire going to the TCI. I don't have a 550 diagram, though. Usually Yamaha is pretty consistent in their wiring between models...

By the way, do you have a 550 diagram? If so, what does it say about these wires?

 

Re: No spark-where to start looking

Go to a Dealer.
Be exceptionally nice.
Tell them you have Yamaha in your blood and are engaged in a labor of love restoring an antique Yamaha.

Ask if they will let you examine the Factory Color-coded Wiring Diagram.

Make it a Kodak Moment.

 

Re: No spark-where to start looking

yes, i have a 550 diagram from the book and from fitz. the wire is stating its sky blue all the way to the neutral switch. and of course....its not. If you take the cover off its blue with yellow tracer i believe ( i can check if you'd like) anyhoos, it splices in with a group of wires next to the side case and leads all the way up to the tci plug. At this plug there is a male connector that the sky blue wire pops into. it boggled my mind.....o well