Oh man I'm So Close.....

So let Me say This first . I am a rookie trying to figure this out. Having fun, yet frusterated LOL.

A little history of this bike. 81 XJ650 with 12000 miles. I know that this bike has had the battery hooked up backwards thanks to a BUDDY who was trying to help(he did after we figured out his mistake) But after that we got the bike running

So the first thing that happened is that the square Diode in head light bucket melted...but She still runs with out it..

• IS THAT OK. Do i need that for the bike?

So fast forward a few months Seemed like everything was working as it should. New headlight, LED blinkers. New Brake light. NEW SEAT.
So I put insurance on for the day just to try her out, I made it about 2kms down the road and I started to blow ignition fuses.
Ended up melting the OFF/RUN switch.

Fast forward ....The Winter... I have replaced the switch, fixed the short, and we are back up and running. But now I have no headlight. I have tested and do not have 12v at the headlight....

• do I need a new relay
• Can you wire in a aftermarket relay?

Any insight would be awesome.

 

Diodes are always critical to any circuit. Looks like it took the polarity abuse and stopped the damage. Someone needs to check your harness from A to Z with a volt meter.

 

I have wondered about that... I had the wiring harness out and I checked what I could, for resistance

 

you need the diode block or install your own diodes and resistor
XJ 650H diode block
white wire from alternator goes to diode and then to your headlight relay. it turns ac from alt to dc for the bike.
the diode resister set runs the oil light test and low oil light. another diode runs sidestand relay


ac to relay would toast it




Your relay may be good . if you did nothing to replace the diode block it means the 2 white wires running to the diode block connector that turn on the headlight relay are not connected through a diode . you need a diode block to turn on headlight relay, or a suitable diode hooked into the white wires

 

So if I found a guy who understands electrical he may be able to build one????

 

Don't skimp on the electrical parts. They take a lot of abuse on a bike. You will end up fixing something over and over. I could make one with the component specs, but it is typically cheaper to just buy an aftermarket module.

 

Well at this point. Would it be better to strip the wiring and go with a minimal diagram. Rewire it

 

Replace the diode module first and see where things are then. Disconnect your accessories and lights, then check for 12v across the leads at each location to get a rundown on what is still nonfunctional. Grab a cheap 12v test light from HFT instead of blowing fuses and light assemblies.

 

Can you get a AFTERMARKET ONE, or should I try to source one from an j650

 

You can buy new OEM or used. Plenty of used ones for under $10.

4H7-81980-M0-00