Electrical voodo

[rombat]

My 1100 maxim was running fine, then I replaced my spark plugs. First my headlight started cutting in and out. Then my fuel gauge showed empty with a full tank. Now the bike will not even turn over, all in the space of 48 hours. The battery shows 13.4 volts and 14.58 volts when it was running. Anyone have any idea where to start. I replaced the fuse block with inline fuses 2 years ago.

[planedick]

Ground

Check the ground connection between the frame and the engine and the battery and the frame. Also two plugs under the tank in the center. White ones with about 6 wires each.

[DiverRay]

Also look at the wires that plug into the ignition switch. The Brown goes to the rest of the harness, and the Red should be from the battery. Also, how old is the battery? Check the voltage when trying to start, just for kicks....

[rombat]

Checked the grounds, are clean and tight. White plugs look fine. The battery is 7-8 years old, but was stored for 4 years of that. It seems solid, the bike lights up bright but will not turn over, not even click. It started fine this morning even after the headlight and gauge issues, now nothing. This all started right after the plug change, could they somehow cause this?

[Incubus]

You may have set a world record with that battery... stored or not.

Patrick

[fredintoon]

Checked the grounds, are clean and tight. White plugs look fine. The battery is 7-8 years old, but was stored for 4 years of that. It seems solid, the bike lights up bright but will not turn over, not even click. It started fine this morning even after the headlight and gauge issues, now nothing. This all started right after the plug change, could they somehow cause this?

Hi rombat and welcome,
I'm in Saskatoon, what part of Sasakatchewan are you in?
I don't see how changing the plugs could make the bike not crank over.
Not fire, yes, say if you mixed up the plug wires.
First, check the fuses. Use the Ohms setting on your multi-meter; the needle should whack right over. Sometimes fuses look OK but they ain't.
If ALL the fuses are good, jumper the bike from your car battery to see what happens.

[rombat]

Thanks all for the ideas so far. Hopefully I have time today to chase them down. Hi Fred, I live in Dalmeny just 15 miles north of you. If it helps here is a timeline of the meltdown. Replaced spark plugs, routine maintenance. Old plugs looked fine. Turned on the key, heard a strange pop(fuse went maybe?),headlight went out. Bike started fine and ran smooth. The next day the headlight worked and I rode to work. On the way home the fuel fuel gauge went to low fuel warning with 1/2 a tank of fuel, it has always worked fine. Filled the tank and the gauge still shows low fuel. Parked in the shop at home and now the bike lights up but will not even turn over.

[fredintoon]

Thanks all for the ideas so far. Hopefully I have time today to chase them down. Hi Fred, I live in Dalmeny just 15 miles north of you. If it helps here is a timeline of the meltdown. Replaced spark plugs, routine maintenance. Old plugs looked fine. Turned on the key, heard a strange pop(fuse went maybe?),headlight went out. Bike started fine and ran smooth. The next day the headlight worked and I rode to work. On the way home the fuel fuel gauge went to low fuel warning with 1/2 a tank of fuel, it has always worked fine. Filled the tank and the gauge still shows low fuel. Parked in the shop at home and now the bike lights up but will not even turn over.

Well, Hi Neighbor!
Give me a call, eh?
Fred Hill, 384-9489
If nobody picks up, talk to the 'droid.

[natemoen]

7 -8 year old battery is VERY impressive. I would change it either way. Old batteries cause mysterious problems sometimes!!

[fredintoon]

- - - Turned on the key, heard a strange pop(fuse went maybe?),headlight went out. Bike started fine and ran smooth. The next day the headlight worked and I rode to work. On the way home the fuel fuel gauge went to low fuel warning with 1/2 a tank of fuel, it has always worked fine. Filled the tank and the gauge still shows low fuel. Parked in the shop at home and now the bike lights up but will not even turn over.

Hi rombat,
I'm not familiar with the XJ but on all the XS's we have, (2 x 650, 750 & 11) the headlight don't come on with the key, it only comes on when the engine fires up.

[crazy steve]

7 -8 year old battery is VERY impressive...

Not really, I've had more than a few last that long. The trick is these are nearly always 'non-sealed' units that have been properly maintained. The 'modern, new-and-improved' sealed batteries don't seem to go more than 3-4 years in spite of what you do.... progress

[rombat]

So far no luck. All of the fuses, wires, connectors,grounds, check out. The battery is the old style.Trickle charge 12 hours once a month during storage is the key! Also only use distilled water. Aways back to the gremlins. I still think it has something to do with changing the plugs. Maybe I wiggled some wire when I was moving the plug wires? Right now there is lots of battery but no signal to the solenoid when I hit the starter. The headlight on XJ's comes on with the key and goes out when the starter is pressed, which is what is happening now, just no juice to the solenoid.

[natemoen]

Have you tried just jumping the starter solenoid to see if you have a problem there?

[bikerphil]

A connection that is often overlooked is the positive at the starter itself. Once I had a similar no start condition, and the starter connection under the plastic cover was corroded. Cleaned it up and everything was fine. JAT

[rombat]

Well some good news, the bike starts and runs fine if you jump the solenoid. The bike has always needed the clutch engaged before it would turn over. I assume this is standard and am wondering where the sensor is that controls the clutch signal? Headlight works fine but the fuel gauge is still acting up.