XJ550 start button problem [SOLVED]

The problem: "push-button" does not engage the bike to crank

Who: a right-hand control switchbox that fastens to handlebar to complete the 'ground'. contains killswitch and pushbutton...all stock wiring on the bike

What: working with an XJ550 Maxim '81 model

When: problem arised when I removed previous owners' wiring for toggle switch directly wired to starter solenoid bypassing the starter circuit. the right-hand control switchbox was missing the push-button, hence a toggle switch was installed by previous owner. Now I'm trying to repair this wiring by going with original push-button style


I am going to go back to normal push-button start mechanism, and have had an XJ wizard member on here install a push-button in the control switchbox for me. This post is to get other members advice too.

As stated at the very beginning, my problem is the push-button now. The killswitch wires (two red colored wires coming to & from killswitch) correctly test with continuity and have power when key is turned on. If the push-button wire (sky-blue color) was correctly working, I would have continuity when I press the push-button in, correct?

I don't.

Here's where I become confused. Because there is no continuity, my suspicion was a faulty connection of sky-blue wire at the base of push-button. So I re-soldered the wire and have cleaned the contact points of the button and the base where wiring is connected. I then used parts from a flashlight (battery & bulb) to make sure the wire & re-soldered connection was good. It checks out and should now provide continuity when hooked into the bikes wiring harness. Or so I thought...

But the problem is still existing (no continuity for the sky blue wire) when plugged into the wiring harness even after checking & confirming that the wiring to switchbox is satisfactory. So you may think the wiring harness is the culprit.

But its not... lemme explain.

Took my right hand control switchbox off my running XJ650 Maxim and plugged it into the XJ550 maxim. Continuity checks out on the killswitch as well as continuity checks out with the push-button mechanism. Fastened to the handlebar, it cranked over the bike and fired without hesitation.

Any suggestions to helping me define what my problem is?? I feel like I'm running in circles trying to chase my own tail. Only thing I haven't done yet will be to put the 550 right hand control switchbox on the running 650 and see if that will tell me anything different.

 

Re: XJ550 start button problem

please... i'm just looking for any suggestions

I hope my explanation was thorough enough. Or maybe it was too much, hence no response over 13 hours

hmm...

 

Re: XJ550 start button problem

First trace that one wire & see if it grounds when you press the button.

 

Re: XJ550 start button problem

Moellear,

If you can't get it straightened out, send it up and I'll wave a magic stick over it....or beat it with a club. Seriously, send it up and I'll do whatever needs to be done for you. I do have a couple more switches, and one just came in on a bike last week. So, I can swap parts around until something's working right. I won't be onto this new arrival for awhile, so if worse comes to worst, I'll swap the whole thing out.....

dave fox

 

Re: XJ550 start button problem

It doesn't. On this control switchbox for the 550. However, I have put my operating, good condition, control switchbox for the 650 on my 550 maxim project bike and it DID work.

So that would tell me its the control switchbox for the 550. However like I said, when I check to see if power is capable of going through that one wire (the sky blue color, only for the push button itself) it checks out fine. And I know so because I re-soldered the wire to the contact point for rear portion of push button mechanism.

Its almost as if a gremlin or "ghostly" feature does not ground out the 550 control switchbox. I don't get it. Could the push button nipple itself have gone BAD???

Thanks Dave for all your help. Last resort I'll send it to you & have you take a look at it. I get the feeling its not the control switchbox however, since power goes through all 3 wire (two red for killswitch & one sky blue for push button). Its only when I push the button that the skyblue wire does not check out for continuity.

I'll see what happens if I put this 550 switchbox on my 650 tonight. But keep the suggestions & brainstorming coming guys!! I need some help <LOL>

 

Re: XJ550 start button problem

guys my "button" is the culprit. I switched control switchboxes; put the 650 one on the 550. put the 550 one on the 650. The 650 control switchbox cranks my 550. The 550 control switchbox does not crank my 650.

I also know my "button" is the culprit by doing the following. I took the "button" assembly apart and touch the very bottom part of the button assembly (its a small plate where the button makes contact with the sky-blue wire) with a battery and mini-light bulb to create an "old-school" flashlight. The sky-blue wire DOES in fact allow electric (from the battery in the flashlight circuit) to flow thru.

As a result, the only missing part of the problem is the button itself and the spring that keeps it away until you push the button inwards. So I pose a question:

DOES THE SPRING NEED TO BE A PART OF THE ELECTRIC FLOW?

weird question I know, but what really makes this situation weird on me is what I describe in the first two paragraphs of this particular post. It don't work as a whole unit. But yet the wiring itself is satisfactory. a little help here guys?!??

 

Re: XJ550 start button problem

well i'm glad I was able to get all the help I could from the eleven thousand or so members on here... jeez

that being aside, I answered my own question. Yes, the spring must properly seat against the button as well as the base plate. Mine wasn't due to a personal mistake I did a couple nights ago. long story short, created a dead circuit on purpose very quickly just to see if electric would flow to the button.

well it did and in doing so slightly melted the button just enough to not have a proper contact area for the spring. This is part of the problem. Also discovered that the connection of sky blue wire to the wiring harness is not properly connected. When i was testing it with "flashlight" bulb and a jumper lead, aparently the jumper lead was touching the wire and not the actually crimped portion where the wiring harness mounts into.

maybe I type too much. maybe nobody cares. maybe since it was friday people don't respond as quickly. maybe I shouldn't have addressed this issue at all. maybe being a 25 year old on a friday evening working with this project bike is not "cool" to other people's standards.

This doesn't qualify me as "Depressed" ...<LOL> hopefully this posting at least helps someone down the road.

 

Re: XJ550 start button problem

Don't worry, we all love you moellear.

 

Re: XJ550 start button problem

For sure go with this:

maybe since it was friday people don't respond as quickly.

I bet that's the issue, sometimes I've waited a couple days before ppl see my post and have time to add their thoughts.

Don't take it personally! We do all love everyone else on here.... in a "luv" way... not "love".. that could get weird lol.