The XJ550 interactive colorized electrical diagram! Update 4

Re: The XJ550 interactive colorized electrical diagram! Update 1

Diode Block: inside the headlight bucket.

Alternator: on the left side of the engine, just north-west of the starter motor, under the round cover below the carbies.

Neutral Switch: on the XJ550 models, it is under/inside the shifter cover (it's a triangular white plastic thing); on all other models, it's a threaded sensor that screws into the bottom of the engine case, inside a sunken cavity, to the left of oil pan.

These switches are not actuated nor connected to the shift pedal; rather, they have a movable plunger that rides in a groove on the internal shifter drum, and when the drum is in the "tranny-in-neutral" position it creates a ground circuit for the neutral circuit, lighting the green light, allowing safety relays to do their job, etc. (that's how they operate on XJ650-1100 models; XJ550 switches work in a "similar-but-different" method but accomplish the same thing).

 

Re: The XJ550 interactive colorized electrical diagram! Update 1

Thanks for the nomination and the info! I have a busy weekend in front of me but will try to squeeze in a bit of diagram updating. I have a few ideas on how to improve it further.

 

Re: The XJ550 interactive colorized electrical diagram! Update 1

X2 8)

 

Re: The XJ550 interactive colorized electrical diagram! Update 1

Not sticky-worthy then? :?

I thought it was a great candidate

 

Re: The XJ550 interactive colorized electrical diagram! Update 1

Update 2013-06-02
Version 1.1.40.

I haven't had much time off from work, and when I did have, I've been focused on rebuilding the bike I first made the diagram for (build thread coming eventually).
Anyway, I have now managed to spend a couple of days improving the diagram with ideas that I have wanted to implement for a while.

A lot of changes!

1. Fixed cable colors that were reversed (e.g "Green & White" is now "White & Green" = White with Green stripe).
Colors left to check: Black/White, Brown/White, Blue/Black, BlueWhite, Blue/Yellow. Any assistance in this would be appreciated.

2. Engine stop switch: Added functional description.

3. Starter button: Added functional description.

4. Dimmer switch: Added functional description.

5. Flasher switch: Added functional description.

6. Horn button: Added functional description. Please verify if this is how you actually use it.

7. Front brake light switch: Added functional description.

8. Side stand relay: Renamed, added relay image, added functional description, added bypass description.

8. Fuel gauge sender: Added popup, added image, added functional description, added resistance levels, added location.

9. Start circuit cut-off relay: Added relay image, added functional description, added bypass description.

10. Starter relay: Added relay image, added functional description.

11. Battery: Added battery type, added charging rate.

12. Fuse box: Added functional description, added replacement advice.

13. Diode block: Added popup, added image, added functional description, added location.

14. Pick-up coil: Added functional description, added location.

15: Ignitor unit: Renamed slightly, added functional description, added unit image.

16: Rectifier/regulator: Added functional description, added unit image.

17: Ignition coil: Added functional description, added unit image.

18: Headlight relay: Added functional description, added bypass description, added relay image.

19: Flasher cancelling unit: Fixed spelling, added functional description, added bypass description, added unit image.

20. Flasher relay: Added functional description, added LED upgrade information, added relay image.

21. Ignition switch: Added functional description, added switch image.

22. Rear brake switch: Added functional description, added switch image.

23. Neutral switch: Added popup, added image, added functional description, added bypass description.
WANTED: better location description, the image alone is inadequate.

24: Oil level switch: Added functional description, added bypass description, added switch image.

25: Reed switch: Added functional description.

26: Horns: Added popup, added image, added functional description, added replacement advice.

27: Clutch safety switch: Renamed, added image, added functional description, added bypass description.

28: Side stand switch: Renamed, added image, added functional description, added bypass description.

29: Cleaned up the code additionally to make it easier to adapt to other bike models in the future.


STILL WANTED: Drawing, location and description of the Alternator.

More functionality on the drawing board.

PLEASE verify if the functional descriptions are correct. I have written them based on my own novice understanding and I don't want to mislead anyone by providing inaccurate information. I would love to not only hear "#6 is wrong, you have mixed up he first and the third step", but also. "#7-14 is correct". You get the idea, helps me sleep at night.

Comments are always appreciated!

/Frank

 

Re: The XJ550 interactive colorized electrical diagram! Update 3

Alternator, generates power to charge the battery and run the bike at over ?2100rpm's? under that your battery is running everything.

Location, on LH side of motor above the tranny in between the starter and the actual cylinders. it has its own cover.

sorry no drawing.

 

Re: The XJ550 interactive colorized electrical diagram! Update 1

Why, oh why is this not sticky yet? it's a great resource & Frank's put in a helluva lot of work for it to just get forgotten... 8O

(free bump!)

 

Update 4

Update 2013-11-23... kind of.
Still Version 1.1.40.

Ok, a lot have happened in my life, and this project has had to wait. I have also completely redone the wiring on my own XJ and can therefore not use it as a reference for continued work and error checking.

I have therefore decided to publish the source file.

I know that many of you wanted to see this done for other models as well, and I have realized that I cannot undertake that task at this point in my life. I feel that that it's better if other enthusiasts can take over (if anyone at all is willing, that is) and build on the work I have done so far.

I hope that I don't disappoint anyone with this decision.

All varieties of the diagram and a short description can be found at http://frankjohansson.com/stuff/xj550/. The download link for the source file is available under "Future plans".

 

Once again, thank you Frank for your work on this diagram & especially thank you for publishing the source file. If I get time over winter I may try a bit of development/refinement and if I get the hang of it might try my hand at XJ900 31A & maybe some 750 diagrams. Baby steps first though, but thank you for the solid ground to start on!

Still can't understand quite why this thread isn't either stickied or in the FAQ area :? still, can't complain as long as the thread gets a "bump" once in a while. It'd be a crime to let it be forgotten after the work that's gone into this!

EDIT-: wow this is going to take a while, going to have to wait till I have enough data allowance to download even a trial of flash cs6 8O