starting issues

I just bought an '82 xj550 as a winter project and my first bike. The guy I bought it from said it had an electrical problem and he didn't know anything about engines so he just wanted to get rid of it. The problem is the ignition switch isn't getting power. So i checked the side stand switch that had continuity when the stand is up none when down. The side stand relay was also good. I tried to check the neutral switch but I couldn't tell what points I was supposed to check for continuity. Although when the bike is in neutral the neutral light turns on not sure if that's a definite sign that its OK but I know the switch is what actually activates that light. So if any one could tell me how to check the neutral switch that'd be great. Also I tried to check the clutch switch but I couldn't find the connector I found a lime green connector not attached to anything with a black/yellow and a blue/yellow wire. It doesn't seem to have any relation to the clutch other than the correct wire colors, but I figured it should be plugged into something anyway. If anyone has any suggestions let me know.
P.s.
The starter solenoid is good as well

 

start by jumping the solenoid real quick to see if it turns over. clutch wire shouldnt matter if the bike is in neutral. i took mine out completley. most of the time it ends up being the push button for the start button or a faulty solenoid. if you hit the button, do you hear a click in the solenoid? and how do you know its not getting power? testing the wires or just because it wont start?

 

Welcome to this great site, Tonyr570.

First things first... did you get your hands on an aftermarket and an OEM shop manual? If this is your "winter project", you need to systematically go over every inch of the bike, using the manuals, to get it back up to running AND safe condition. Always assume that the PO (previous owner) knew nothing about maintenance, and learn what you can to make sure you know as much as you can -- then do it.

Search around this forum first for "bike resurrection" threads. Much has already been written that's required reading for someone like you in the cool position of getting their first XJ. Your assignment, should you choose to accept it, is to find and apply all that great info.

Don't do what most people do... get it running, hop on a tired old bike, and trust their lives to a two-wheeled deathtrap. Take it from a reformed deathtrap rider.

Also, it's a good idea to edit the "signature" line in your profile to add the year and model (Seca or Maxim?) of your XJ, so it's in every post you make, and people won't have to ask.

 

Tony, I just went thru the same scenario with my 82 XJ750. I wrote about it here. If the neutral light comes on the switch is (likely) good. The clutch switch terminals are inside the headlight housing, but if the neutral switch is good, then it shouldn't matter. There are several relays under the tank you should check. For starters, you should hear them click when you turn the ignition on. I got a Haynes manual (~$30), and it has some good (and easy) diagrams of the starting system, along with steps to test the various relays.

 

The aftermarket book for the 550s is the Clymer and the electrical diagrams are sad.

PM me with an email address and I'll send you the pertinent pages from the factory 550 book.

 

Thanks for all the responses, I have the Yamaha repair manual some things are Vague though. The solenoid is good and The reason I know there's no power at the switch is I checked it with a multimeter. @secamaverick I plan on going over every inch of this thing don't worry. So it sounds like you guys are saying the clutch switch doesn't matter but don't all three of the switches need to be set to start the bike? And if its not the clutch switch and the side stand and neutral switches are good what else should I check?

 

Tony,
I would definitely take Fitz up on his offer to provide you some relevant pages. troubleshooting an electrical circuit without a schematic is frustrating at best..

For starting in neutral (neutral switch good), side stand may be up or down and clutch may be in or out.

For starting NOT in neutral, sidestand must be up and clutch must be pulled (clutch and sidestand switches must be good.

While I am not an "XJ Wizard" I did just go thru this, and hrere's what I checked **on my 750**:
1) Battery
2) Fuses
3) Starter relay (solenoid) - next to battery
4) Starter motor - disassembled, cleaned and greased
5) Clutch switch - connections in headlight bucket
6) Starting circuit cut-out relay - under tank, test for: coil good, cantacts close, diode checks good
7) Sidestand relay - under tank above carbs,test for: coil good, cantacts open when relay energizes
8 ) Engine stop switch and Engine start switch - black plug under tank
9) Neutral switch - green light on, switch good
10) Sidestand switch - plug near battery and solenoid

 

hey just figured I would update anyone who cared. Turns out I was going too deep, one wire going to the run/off switch was slightly corroded and had no continuity. cleaned it up and it is done.

 

Good going.

Here's some stuff that's not in the factory book, and if it's in the Clymer at all it's not covered very well:

BIGGIE: http://xjbikes.com/Forums/viewtopic/t=15874.html

http://xjbikes.com/Forums/viewtopic/t=19538.html

http://xjbikes.com/Forums/viewtopic/t=35134.html

http://xjbikes.com/Forums/viewtopic/t=25058.html

These are just to "augment" the manuals:

http://xjbikes.com/Forums/viewtopic/t=29541.html

http://xjbikes.com/Forums/viewtopic/t=14827.html
http://xjbikes.com/Forums/viewtopic/t=29209.html

http://xjbikes.com/Forums/viewtopic/t=31061.html

 

Thanks a lot those are awesome threads. I already got a new caliper for the front brake the rear seem ok no rust and the shoes look almost new. As for the bearing what are the signs of a bad one? I know the signs of a bad wheel bearing on a car so I can't believe it's too different if at all so I think that's good too. There don't seem to be any signs of anything leaking from the engine. Is there any other known issues I should go over or anything I should just replace a to be safe? I've heard you should treat the gas tank to get rid of any rust on a bike that's been sitting not sure if I have to though. I'm going to clean the carbs up but other than that this thing looks like it's in tip top shape. I appreciate all the advice and help.

 

A NEW one, or just a different 30-year old one? Unless it's brand new it's still gonna need to be rebuilt...

 

A 30 year old one but I rebuilt it before I put it on. the piston in mine was cocked and I couldn't get it out for anything so I just bought one off Ebay and already had the rebuild kit since I was gonna do mine.

 

good job.

 

Thanks so is there anything else I should check or just replace?