Starter relay XJ550

My old (83) xj is in the final stages of a complete rebuild. When I turn on the Ignition switch, the starter runs continuously... Would a faulty starter relay cause this problem ? The starter solenoid seems to be ok, but the ohms test of the starter relay does not match the service manual specs. I have been very careful with the reassembly of the wiring harness and components Cleaned & dielectic grease on all contacts. The battery is good and fully charged. I have a wiring diagram HELP !!

 

The starter solenoid must be closed for the starter to run. So a control circuit for it is stuck closed.
I would start looking at the start button on the handlebar control to see if you have a stuck button or broken wire that's shorting out. Follow that circuit back to the solenoid with your wiring diagram.

 

The starter button assy is new and checks out ok. The starter relay does not check out properally according to the manual.(chapter 7) A new one is $95.00 from a dealer. I will look for a good used one at a bike recycler. I pried the cover off the starter relay and put a piece of paper between the points. they are open when the key is off, but close when the key is turned on. the paper prevents the points from contacting and the starter from engaging. The wiring harness is in good shape. The bike has only 9500 original KM on it. It has sat neglected for many years but is in really good shape, so it's a good winter project. any other suggestions ?

 

I would not replace the solenoid without tracing down the control circuit to find why the solenoid is getting voltage (it must be getting voltage for the contacts to pull in when the key is turned on) without pressing on the start button.

The diagram I have shows a diode in the circuit between the oil light and the start button. If the diodes bad, you may be getting a ground thru this side of the wiring.

 

Yes, I see the diode in the starting system diagram (page 164, clymer manual). I went to a local boneyard to-day and we checked a couple of identical used starter circuit cut off relays. They tested the same when hooked up to a battery, The diode in the relay tests OK according to my Fluke meter. I'm stumped on this one :cry: Next I will run a wire from the solenoid direct to the starter button to replace the blue/white to see if there is a short in the wiring harness. I'm gettig grey hair over this one.