Something spooky in the wiring

1982 XJ750 Maxim - bunch of problems...sometimes starter button doesn't work, but will if you wait for it; sometimes headlight won't come on, but will if you shut it off & start again; lately the check sensors in the center of the instrument panel have been coming on while riding like it does when you first turn on the key, then will run through the sensors like it does after you first start it. When this happens the headlight will dim down, then brighten back up when it finishes its "check". Now I've noticed that when it does this, dim lights come on in the turn indicators on the panel but the actual lights won't work, and last night coming home from work at midnight the headlight went right out completely for about 15 seconds, then came back on. I've replaced the battery & fuse box, checked the alternator brushes (they're good), and taken the instrument panel off & checked all the connections. Does this sound like stator problem or something? It is definitely getting worse, does it unprovoked now. When it first started it seemed to be if I hit a bump, railway crossing, or something. Any ideas?? Thanks

 

Sounds like a short somewhere. Check the grounds and make sure there is no corrosion on any connection anywhere. Then replace the fuse box with a modern one and get rid of the glass fuses.

 

He did that.

You have an obvious loose connection (or bad ground) somewhere.

Which is being affected by bumps in the road, etc. Doubt it's the stator.

Start in the headlight shell.

If you don't find it, pull the tank and start "wringing out" the harness and connectors. It could also be back by the battery/regulator/rectifier/feeds to the TCI and fusebox area.

Doubt it's an actual "short." Sounds more like an intermittent "open" which means loose connection or compromised wire/connector.

 

So, rectifier/regulator is definitely blown, melted the plug right together. Still thinking stator as it started power surging so bad it nearly blew the headlight. I found parts in Wisconsin & just waiting now. I also pulled the headlight & the instrument cluster & checked all the connections in there first, then tried it again & got the power surge. Hope the parts I found do the trick.