1. Some members were not receiving emails sent from XJbikes.com. For example: "Forgot your password?" function to reset your password would not send email to some members. I believe this has been resolved now. Please use "Contact Us" form (see page footer link) if you still have email issues. SnoSheriff

    Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

XJ650 electrical issues

Discussion in 'XJ Technical Chat' started by Tony7745, May 19, 2023.

  1. Tony7745

    Tony7745 Member

    Messages:
    57
    Likes Received:
    0
    Trophy Points:
    6
    Location:
    Jersey Mills, PA
    In the never ending quest to get my 81 XJ650 started that was running last month. I've replaced the right side handlebar switch and the relay under the TCI module. The starter will engage if I jump the solenoid but the signal from the handlebar switch doesn't activate it. The ground to the engine case and frame is good. The headlight, taillight and license plate light all work. The horn, turn signals, neutral and low oil light don't work. It seems to not have a clutch switch and I'm at a loss because it's gotta be something simple.
     
    Tony7745, May 19, 2023
    #1
  2. Timbox

    Timbox Well-Known Member

    Messages:
    2,642
    Likes Received:
    913
    Trophy Points:
    113
    Location:
    Wisconsin, Tomah
    You will have to see if the trigger wire from the starter button to the solenoid is working. I have had several XJ's that with age the wire brakes. Not in the bar swx but in the wiring harness its self. Just running a new wire along the wiring harness do the solenoid trigger spot fixed the issue.

    Good luck.
     
    Timbox, May 19, 2023
    #2
  3. jayrodoh

    jayrodoh YimYam

    Messages:
    2,578
    Likes Received:
    1,147
    Trophy Points:
    113
    Location:
    Cleveland
    The FSM has a great section on troubleshooting the starting system. I recommend getting one if you don't have it.

    The starter solenoid gets it ground from the starter button, pretty easy to check if that is okay. The solenoid gets it positive signal from the stop/run switch and the safety circuit which includes the neutral switch, clutch switch, starter cutoff switch, and diode pack. Not a difficult system to troubleshoot but it helps to have the manual. Does the oil light light up when you press start with the key on?

    The relay below the TCI is for the headlight.
     
    jayrodoh, May 19, 2023
    #3
  4. Bryce W

    Bryce W Member

    Messages:
    98
    Likes Received:
    22
    Trophy Points:
    8
    Location:
    Virginia
    Check the small wire attached to the solenoid with a multimeter. If memory serves, you should see a constant 12ishvolts, but when you press the starter button, it should ground out to 0 volts. If you are getting that signal, try flipping around the solenoid... Hooking it up backwards can cause the issue of the button not cranking... among other things, but Id check that wire first.
     
    Bryce W, May 19, 2023
    #4
  5. Rooster53

    Rooster53 Well-Known Member Premium Member

    Messages:
    1,988
    Likes Received:
    795
    Trophy Points:
    113
    Location:
    North, FL
    That's a pretty good indicator of a blown signal fuse, excepting the oil light that is powered by the ignition fuse. Have you checked fuses? Do you have and upgraded fuse box?
     
    Rooster53, May 19, 2023
    #5
  6. Tony7745

    Tony7745 Member

    Messages:
    57
    Likes Received:
    0
    Trophy Points:
    6
    Location:
    Jersey Mills, PA
    It turns our that something in the headlight bucket was shorting out causing the fuses to pop. All fixed now ! Thanks for the help. I do want to upgrade to a touring bike like the venture royal or goldwing.
     
    Tony7745, May 21, 2023
    #6

Share This Page