Sunday, March 16.

BREAKING NEWS

  • >>19-Apr-2010: XJ650 Hardtail Chopper
  • >>07-Apr-2010: The New Everything Yamaha XJ650 Site
  • >>06-Apr-2010: Hacked
  • >>23-Jul-2009: XJ650 Adventure
  • >>26-May-2009: Green with Envy
  • >>06-Apr-2009: HOW TO: Bench Synch your Carbs
  • >>30-Mar-2009: HOW TO: Install a Headlight Modulator
  • >>27-Mar-2009: Red Beast
  • >>12-Jan-2009: HOW TO: Test a Relay
  • >>11-Jan-2009: Silver Special Maxim

XJ650 Hardtail Chopper

I came across this chopper on my countless hours spent looking at pictures of Yamaha Maxim and Seca motorcycles. I really loved the clean look of this hardtail chopper. I had the misfortune of losing my muffler on a midnight ride into Istanbul, Turkey and I remember how loud it was. Looking at the missing muffler on this motorcycle makes me cringe thinking about the noise this bad boy must unleash. The owner of this Yamaha XJ650 hardtail is a g...

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The New Everything Yamaha XJ650 Site

Well after many hours in front of the computer I have given the Everything Yamaha XJ650 site a complete face lift. I hope you like the new look. T...

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Hacked

Over the weekend this site was hacked. I'm not sure why, it's not as if we have a huge following. I'm pretty sure it's the Honda CBR crowd jealous...

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XJ650 Adventure

I know alot of people just come to this site for the great 'How-To's" and to get ideas for their XJ650 restoration projects but I wanted to direct...

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Howto

HOW TO: Bench Synch your...

This is a "How-To" on bench-synching carburetors. I've noticed quite a people (me being one of them) searching for clear instructions on how to do this. At some point recently I came upon them, but I can't seem to find them anymore. So, I decided to

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Fuel

HOW TO: Bench Synch your...

This is a "How-To" on bench-synching carburetors. I've noticed quite a people (me being one of them) searching for clear instructions on how to do this. At some point recently I came upon them, but I can't seem to find them anymore. So, I decided to

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Electrical

HOW TO: Install a Headli...

Have you ever seen those motorcycles coming at you with those headlight modulators? The pulsating headlight makes them very noticeable to other motorists. Unfortunately, these units can be rather expensive. After doing some research, I've come up wi

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Engine

Readersrides

XJ650 Hardtail Chopper...

I came across this chopper on my countless hours spent looking at pictures of Yamaha Maxim and Seca motorcycles. I really loved the clean look of this hardtail chopper. I had the misfortune of losing my muffler on a midnight ride into Istanbul, Turk

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Chasis

HOW TO: Change your fork...

You noticed it sometime back, but ignored it hoping it would go away. But, it hasn't. In your embarrassment, you quickly wipe off your fork tubes when meeting friends for fear that they might say something. Worse yet, it's gotten so bad that your fr

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Travel

XJ650 Adventure...

I know alot of people just come to this site for the great 'How-To's" and to get ideas for their XJ650 restoration projects but I wanted to direct you to another side of owning a Yamaha XJ650... riding! As the administrator of this blog you can gues

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Ads

XJ650 Swarmed by Gypsies in Albania

Daily Deals

HOW TO: Test your starter circuit

Posted on January 5, 2009 and filed under , , . You can follow any responses to this entry through theRSS 2.0 . You can leave a response or trackback to this entry from your site

xj650 blog Wiring DiagramStart with the bike on the center stand with side stand up and the transmission in neutral. You will also want the ignition switch turned to on and the kill switch turned to on. The numbers in the picture coincide with the steps listed below.

1. Test the voltage at the battery. It should read at least 12.5 volts. Charge and retest as needed.

xj650 blog Solenoid Shorting2. Using an old screwdriver, short across the two large terminals at the starter solenoid. This will bypass the solenoid and allow the starter to crank the engine. If the starter doesn't crank, perform a continuity test between the negative battery terminal and the engine case. If you read no resistance (or almost no resistance), repair or replace the starter. Otherwise, repair or replace the ground cables and retest.

xj650 blog Solenoid Pigtail3. Locate the pigtail from the starter solenoid and unplug it. Using a jumper lead, hook the Red/White wire from the solenoid to the battery's positive terminal. Using another jumper lead, hook one end to the solenoid's Blue/White wire. Momentarily touch the other end of this lead to the battery's negative terminal. If the solenoid is functioning properly, the solenoid should click and the starter should begin cranking the engine. Repeat this step several times to ensure the integrity of the solenoid. If nothing happens, repair or replace the starter solenoid

4. If the solenoid checks out, hook your continuity tester between the battery's ground terminal and the Blue/White wire coming from the bike's wiring harness for the starter solenoid (solenoid pigtail unplugged). It should read an open state while the starter button is not pressed. When you push in the starter button, the tester should then read a closed state. If there's no change, inspect, clean, or replace the starter button switch and its ground and retest.

5. Using your voltmeter, hook its ground wire to the battery's negative terminal and its positive wire to the Red/White wire coming from the bike's wiring harness for the starter solenoid (solenoid pigtail unplugged). The meter should read 12 volts (approx.) if the bike is in neutral, and/or the clutch lever is squeezed and side stand is up with the key on and the kill switch on. If not, inspect the wire coming from the starter circuit cut-off relay for any breaks or chaffing. If the wire looks good, go to the next step.

xj650 blog Starter Circuit Cut Off Relay6. Remove the left-hand side cover to gain access to the starter circuit cut-off relay. Using your voltmeter, hook its ground wire to the battery's negative terminal and its positive wire to the Red/White wire coming from the kill switch (starter circuit cut-off relay pigtail unplugged). The meter should read 12 volts (approx.) if the ignition switch is on and the kill switch is on. If not, you will need to inspect, clean or replace the 20A Main fuse, the ignition switch, the kill switch, or the wiring between them. If you measure 12 volts (approx.), go to the next step.

7. Hook your continuity tester between the battery's ground terminal and the Sky Blue wire coming from the bike's wiring harness for the starter circuit cut-off relay (relay pigtail unplugged). It should read an open state while the transmission is in gear. When you shift into neutral, the tester should then read a closed state. If there's no change, inspect, clean, or replace the neutral switch and its ground and retest. If it checks out, proceed to the next step.

8. Hook your continuity tester between the battery's ground terminal and the Black/Yellow wire coming from the bike's wiring harness for the starter circuit cut-off relay (relay pigtail unplugged). It should read an open state while the clutch lever is released and/or the side stand is down. When you squeeze the clutch lever and the side stand is up, the tester should then read a closed state. If there's no change, inspect, clean, or replace the clutch and side stand switches and their grounds and retest. If they check out, proceed to the next step. (Note: some models may not have a side stand switch.)

9. If all previous tests have passed, replace the starter circuit cut-off relay and try to start the bike again. If it still doesn't start, have your bike exorcised of demons by a Catholic priest and retest as there's really nothing else that would keep your bike from cranking over.

(Written by Don Bangert Author of several How-To's and the blog, The Path Less Traveled.)

1 Response for “ HOW TO: Test your starter circuit”

  1. Unknown says:

    Excellrnt got bike fired up after 3 years and wiring harness replacement. Works on turbo

     

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Recently Commented

  • Anonymous says:
    How would I get some of these parts cause I would like to do this but different color
  • Anonymous says:
    Excellrnt got bike fired up after 3 years and wiring harness replacement. Works on turbo
  • Anonymous says:
    Great how to thank you for the information
  • Anonymous says:
    I need to replace my flasher for my signals, any idea where i can get a manual?
    [[More detail]]
  • Elvis Glazier says:
    Some borders are harder than others. This year I did the remainder of Eastern Europe plus Turkey. I...[[More detail]]
  • Derek says:
    I lived in Adelaide for two years and almost bought a KLR 650 to do some bush riding. I'm back...[[More detail]]
  • Derek says:
    Nice looking xj. I'd love to do that ride. I've done the whole "across America"...[[More detail]]
  • Anonymous says:
    excellent article! thanks for taking the time to post it!!! in reference to the ? about 10w-30 I...[[More detail]]
  • Anonymous says:
    Air pressure in the shocks?
    Adjust it on the center stand or on the side stand? good blog.
  • Mark Lyons says:
    The article on how to change fork seals is excellent.
    I plan on performing this soon on my...[[More detail]]

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