XJ1100 Bike dies when running

[BA80]

Had a problem similar to yours, the bike would cut out at any given time whenever it felt like it. After months of dealing with this, it turned out to be a bad 4 wire connector at the TCI, the terminals had stretched and weren't making a good connection. Might try taking the terminals out of the connector plug and closing them up some with a pliers. I just replaced mine with a new connector and terminals and have not had an issue since.

Kinda what I was thinking too. That or the plug behind the fuse panel.

Also, if you have another TCI you could plug in and see how that works.

[HalfCentury]

Sounds like the starter solenoid...contacts inside get corroded and the starter button doesnt always get the contact to engage the starter solenoid...I had that issue...but the bike never died while running...just the starting difficulties

Here is what I did. I checked the ignition circuit and it looks good. Tried to start it and it would not crank at all. Studied the schematic and the easiest thing to try without dismounting the tank is to hot wire the starter relay. I did just that and it fired up immediately and better than it usually does from the spaghetti OEM wiring.

I tried it a bunch of times and it fired up immediately every time. I installed some ring terminals and spades to connect the starter relay to the battery. One tiny tap of the ground spade and she fires up instantly. Its a beautiful feeling. Now to find out what exactly is wrong with the interlocks or the cutoff relay.

[HalfCentury]

Had a problem similar to yours, the bike would cut out at any given time whenever it felt like it. After months of dealing with this, it turned out to be a bad 4 wire connector at the TCI, the terminals had stretched and weren't making a good connection. Might try taking the terminals out of the connector plug and closing them up some with a pliers. I just replaced mine with a new connector and terminals and have not had an issue since.

I will fix the start problem and then drive the bike around the neighborhood to see if it still dies. If it does, I will check the TCI plug as you suggest. Thanks for the tip.

[HalfCentury]

Today I drained and removed the tank, found the cut-off relay, pulled it all back as far as possible. It is now just in front of the tank mounting bolt/plate/oval gasket.

Removed the cut-off relay. Created a spade short and installed on the relay socket from Rw wire to Rw wire.

Re-mounted the tank. Poured in a gallon or so of gas and fired it up. It starts every time.

The neutral light remains operational. The Engine Stop switch remains functional. Of course, none of the safety interlocks are functional so care is required not to do something stupid but 8 years of owning XJs should help in the interim.

Drove it around the neighborhood for about 8 miles. Gave the neighbors severe deja-vu sightings of the XJ.

I will bench test the cut-off relay to see what is up if anything.

No more road trips until the electrical stuff is sorted out and while I have the tank off for the electrical repairs, it will be time for valve clearances and carb attention, new manifold boots, etc.

cheers

[motoman]

Today I drained and removed the tank, found the cut-off relay, pulled it all back as far as possible. It is now just in front of the tank mounting bolt/plate/oval gasket.

Removed the cut-off relay. Created a spade short and installed on the relay socket from Rw wire to Rw wire.

Re-mounted the tank. Poured in a gallon or so of gas and fired it up. It starts every time.

The neutral light remains operational. The Engine Stop switch remains functional. Of course, none of the safety interlocks are functional so care is required not to do something stupid but 8 years of owning XJs should help in the interim.

Drove it around the neighborhood for about 8 miles. Gave the neighbors severe deja-vu sightings of the XJ.

I will bench test the cut-off relay to see what is up if anything.

No more road trips until the electrical stuff is sorted out and while I have the tank off for the electrical repairs, it will be time for valve clearances and carb attention, new manifold boots, etc.

cheers

While at it, remove the kill switch, disassemble and clean contacts. This also completes the start/ running circuit. Careful the internal teeny spring doesn't flip into nowhere land upon disassembly. Doing this can and will save you a 'non-running' issue down the road...........and hopefully not 200mi. from nowhere!

[HalfCentury]

While at it, remove the kill switch, disassemble and clean contacts. This also completes the start/ running circuit. Careful the internal teeny spring doesn't flip into nowhere land upon disassembly. Doing this can and will save you a 'non-running' issue down the road...........and hopefully not 200mi. from nowhere!

That is on the list along with obtaining a container of Evapo Rust. I also plan to pack a copy of the wiring schematic from now on and extra wire and connectors to hot wire the starter.

[motoman]

That is on the list along with obtaining a container of Evapo Rust. I also plan to pack a copy of the wiring schematic from now on and extra wire and connectors to hot wire the starter.

Take a cup of Evapo Rust and throw all kill switch pieces in it including the switch(it WILL make internal pieces and the orange center piece on switch look new again).

[Jerry]

tying the wires together would kill the bike every time you put it in gear

Actually, the reverse is true. Tying the wires together makes the circuit think the side stand is always in the UP position.

[trbig]

Everything I've ever used Evaporust on, it leaves a black nasty coating on.

[motoman]

Everything I've ever used Evaporust on, it leaves a black nasty coating on.

Hmmm.....interesting, have never had that happen before.

[BA80]

hmmm.....interesting, have never had that happen before.

+1.............

[trbig]

Seriously? Every rusty tool or part I've ever soaked in the stuff came out with a black carbon looking crud all over it.

[BA80]

Seriously? Every rusty tool or part I've ever soaked in the stuff came out with a black carbon looking crud all over it.

Wipe it off.

I cleaned 2 tanks (first one had holes in it) for the green bike with it. It worked great.

[motoman]

Today I drained and removed the tank, found the cut-off relay, pulled it all back as far as possible. It is now just in front of the tank mounting bolt/plate/oval gasket.

Removed the cut-off relay. Created a spade short and installed on the relay socket from Rw wire to Rw wire.

Re-mounted the tank. Poured in a gallon or so of gas and fired it up. It starts every time.

The neutral light remains operational. The Engine Stop switch remains functional. Of course, none of the safety interlocks are functional so care is required not to do something stupid but 8 years of owning XJs should help in the interim.

Drove it around the neighborhood for about 8 miles. Gave the neighbors severe deja-vu sightings of the XJ.

I will bench test the cut-off relay to see what is up if anything.

No more road trips until the electrical stuff is sorted out and while I have the tank off for the electrical repairs, it will be time for valve clearances and carb attention, new manifold boots, etc.

cheers

Engine STop/Run switch may be functionable, but that doesn't mean a thing. The internal contacts is what completes the running circuit. Better pull that switch apart and clean contacts ASAP before the 'won't stay running' leaves you 200mi. from nowhere!

[BA80]

Better pull that switch apart and clean contacts ASAP before the 'won't stay running' leaves you 200mi. from nowhere!

If you're going to let a little thing like a dirty connection leave you stranded, you better look for another bike. Or better, another hobby.