need help troubleshooting

I have an 82 xj550, i live in northeast ohio and just attempted to to start the bike mid winter. I have the battery still connected to the bike, but on a charger. when i went to push the start button, something shorted, sparked and the electricity went dead. a few seconds later the electricity came back, but when i went to push the start botton, nothing happened. im thinking it is she starter relay even though it is less than a year old. All the fuzes seem fine and i was able to push start it and run it for about 10 minutes before it cut out. (she isnt a cold weather machine). Can anyone give me some troubleshooting tips to pinpoint the exact problem before i order another part? thanks

 

Sounds like a poor connection at the battery, starter relay or frame ground. You get a little bit of a connection that will carry enough current to run the accessories. Then when you hit the start button it draws enough amperage to burn that small spot away. Everything is dead until the connection moves a bit then it all comes back on until you try to start again.

It probably died when the thing moved again and you lost the connection (it won't run without a connection to the battery). Fix it before you fry your regulator/rectifier.

I have a GMC truck that did that often until I completely rebuilt the battery connectors.

 

Im pretty sure the connections are good to the relay and the battery. i bypassed the battery and tried to jump it from the connectors and nothing happened. where is the frame ground located so i can check that. - thanks

 

There is a ground to the back of the motor and to the bottom of the battery box. You can't bypass the battery. It won't work. Easiest thing to do is disconnect the starter and reconnect. Disconnect the battery, solenoid and grounds and reconnect. Also, check the fuse box. The terminals tend to break for no reason. May be a good fuse but bad terminal.

 

You have to be real careful screwing around "bypassing" and jump-starting/running off a booster, etc., you can do some serious damage.

If you have the original fusebox, don't go by appearances; rebuild (for the "purists") or replace (for the pragmatists) it. Either way, the original clips will break on you for no apparent reason, and all on their own. Original fusebox=bad.

It sounds to me as though you don't have a manual. YOU NEED TO GET ONE.

In the meantime, if you will PM me with your email address, I will send you scans of the starting circuit and charging circuit diagnostic pages from the factory 550 book, along with wiring diagrams.

Pull the battery out and put it on the charger.

Wait until spring. Meanwhile, check out the starting/charging system using the materials I will send you.

 

you guys are great, thanks ... is there any test or procedure to find out if it NOT the starter relay?

 

The only thing the starter relay could affect is the starter. Your first post sounded like all the electric died. That won't be a starter relay.

As I pointed out earlier you need to have a close look at the electrical connections. If you've still got the original fuse box that could also be your problem, particularly the main fuse in this case.

It's also possible, but less likely, that you have a poor connection internal to the battery.

 

Pull up the seat and make sure that you didn't have a mouse get into the airbox area and eat some of the wiring harnes.

Pull the battery side cover off again and make sure the battery strap didn't break. If the battery slides forward, the pos. terminal can contact the frame.

The loss of electric and then gaining it back later, would also indicate that the battery is a bit low, and you ended up having to wait til the reserve built up enough again.

Keep trying things as we bring them to you, and we'll all erventually get you going again.

Dave

 

Ok guys thanks - if this helps i will tell you that i did replace my original fuzebox and fuzes and the battery and starter relay are both less than a year old...i guesse that makes it sound like i need to check some wires and connections ...

 

http://www.xjbikes.com/Forums/viewtopic ... relay.html

Here is Gamuru's starter troubleshooting guide. With pictures !

 

can anyone tell me some of the symptoms of a fried regulator?

 

The reg / rec should only allow current to flow in one direction, if you have a workshop manual there is a chart which shows you what pairs to check.