| XJ4Ever.com PO Box 98393 Atlanta, GA 30359-8393 Info@xj4ever.com
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ELECTRICAL SYSTEM:
--Starting System: Battery, Battery Cables, Solenoid, Starter Motor, Starter Switch, Relay, and related hardware, etc.
STARTING SYSTEM PARTS:
BATTERIES:
Brand new OEM and replacement batteries will certainly solve those slow or no-start problems, but before you buy a battery............read on to determine whether you really need a battery, or whether your situation is due to some other cause.
Of course, if you determine that your battery is ready to take that trip to the great lead-acid Heaven in the sky......or, actually, to a recycling center, such as a local auto parts store........then we have a variety of choices for your specific bike.
How do I know if my battery is good?:
Is it your battery, or your charging system, or something in-between?
The best way to know for sure is to use a multimeter (voltmeter) attached directly to your battery positive and negative terminals, and observe the following:
1) with the engine and all electrical accessories off, the battery should read a minimum of 12.8 volts DC. If not, the battery is either not fully charged, or it is bad (it is incapable of holding a full charge). Charge the battery fully and check again; if the reading is less than 12.8 volts, the battery is bad and should be replaced.
NOTE: most manuals describe checking the specific gravity of each battery cell electrolyte (fluid) as the preferred method of checking the condition of the battery. This reading should be between 1.2650 - 1.280 per cell. If a fully charged battery cannot reach these levels in all cells, then that cell is bad and the battery should be replaced.
2) If the first test above passes, leave the multimeter hooked up to the battery terminals, and press the starter button. While the starter is engaged (but before the bike starts), the battery voltage should be 9.5 volts or greater. If not, then this signals either a bad battery, very dirty or weak electrical connections, or it could be a incredibly problematic starter motor (not likely; it's probably the battery!).
3) if you run into this specific problem:
* "There were a few times when I cranked it, that it ALMOST started. It would start to fire immediately as I let off the start button. But it just wouldn't catch.
Then this is a symptom of a weak battery, due to any number of causes.......
What happens is that as the starter is being engaged, it gobbles up battery voltage. As soon as the start button is released, you now have full battery voltage available TO THE IGNITION CIRCUIT (including the pick-ups, the TCI, and especially the coils), and in that instant when you release the starter button, the coils get enough voltage to produce an adequate spark while the motor is still (by inertia) turning over. If everything is in a great state of tune, the bike will normally kick over. If not, you get the "almost fires" situation explained above, so.........
Test the battery voltage WHILE THE STARTER IS ENGAGED (a voltmeter across the + and - terminals of the battery is all that's needed). It should remain above 9.5 volts while the starter motor is engaged but without the engine running. If it drops below that level while the starter is active, then that's the "problem", and the cause of that problem must be determined and remedied (usually a sign of a bad battery, or it could be a incredibly problematic starter motor).
4) Your charging system output VOLTAGE should be checked, again at the battery terminals, while the engine is running. The measured voltage should be:
* 14.2 - 14.8 Volts at about 2,000 rpms for all non-X models, and the same voltage for "X" models, but at about 3,000 rpms. Again, you would measure these voltages at the battery terminals with your voltmeter.
NOTE: If your alternator is outputting more than 14.8 volts to the battery, your regulator-rectifier unit is bad and should be replaced. Over-charging a battery will quickly ruin it, and may cause severe damage or failure of other electrical components, such as the TCI or the computer monitor system (on bikes so equipped).
Here's your cheat sheet on all of the above:
Static Battery Voltage Test
Prior to conducting this test, make sure the battery has not been
recently charged. You must wait at least one hour after charging
your battery to conduct this test.
a) Adjust voltmeter to DC volts (20 volt range).
b) Place voltmeter leads to the battery terminals (positive to positive and negative to negative).
c) Read voltage and refer to the chart below.
State of Charge:
100% Charged with Sulfate Stop:
Using a syringe Hydrometer: 1.280
Using a Digital Voltmeter: 12.80 volts
Using a Floating-Ball Hydrometer: 5 balls floating
100% Charged:
Using a syringe Hydrometer: 1.265
Using a Digital Voltmeter: 12.60 volts
Using a Floating-Ball Hydrometer: 4 balls floating
75% Charged:
Using a syringe Hydrometer: 1.210
Using a Digital Voltmeter: 12.40 volts
Using a Floating-Ball Hydrometer: 3 balls floating
50% Charged:
Using a syringe Hydrometer: 1.160
Using a Digital Voltmeter: 12.10 volts
Using a Floating-Ball Hydrometer: 2 balls floating
25% Charged:
Using a syringe Hydrometer: 1.120
Using a Digital Voltmeter: 11.90 volts
Using a Floating-Ball Hydrometer: 1 ball floating
0% Charged:
Using a syringe Hydrometer: less than 1.100
Using a Digital Voltmeter: less than 11.80 volts
Using a Floating-Ball Hydrometer: 0 balls floating
Starting Load Test:
a) Adjust voltmeter to DC volts (20 volt range).
b) Place voltmeter leads to the battery terminals (positive to positive and negative to negative) .
c) Watch the voltmeter as you start your motorcycle, but before the engine is running.
d) If the voltage drops below 9.5 volts, the battery has very low capacity and should be replaced.
Basic System Operation Test:
To test and see if the alternator is actually getting power to it (along the brown and green wires) you verify whether a magnetic field is being created inside the rotor and stator. Be sure to use a thin feeler gauge when performing this test, since the magnetic field being created is not all that strong outside the generator cover….but it will exist if the system is performing.
Hold the extended feeler gauge blade and 1/4” away from the AC generator cover and when the key is turned on the feeler gauge should pull towards the cover. The rotor should be receiving maximum excitation when the engine is not running. You should be able to measure about 12-volts on the brown wire, and approximately 1.8-volts on the green wire. The voltage regulator controls the low side (green wire) and will raise and lower the voltage based on internal voltage sensing within the regulator.
Charging System Tests:
a) Adjust voltmeter to DC volts (20 volt range).
b) Place voltmeter leads to the battery terminals (positive to positive and negative to negative).
c) Start the engine.
d) Bring engine up to approximately 2,500 rpm's.
e) Compare the voltage reading to the specification given below:
For all XJ-series models, the maximum available charging output VOLTAGE should be as follows (all values are approximate):
* approximately 500-2000 rpms: 12.6 volts gradually increasing to 14.2 volts
* 2000+ rpms: 14.2 volts up to about 14.8 volts, with a maximum of 14.8 volts (all models except XJ700-X and XJ750-X)
* 3000+ rpms: 14.2 volts up to about 14.8 volts, with a maximum of 14.8 volts (all XJ700-X and XJ750-X)
NOTE: the voltage reading must be approximately 14.0 - 14.5 volts to properly charge an AGM battery......anything less, and you will quickly kill these type batteries!
If your charging voltages are too low, suspect the alternator brushes first, then perform the alternator stator and rotor checks as described in the Alternator Section elsewhere in the catalog.
If your charging voltages are too high, suspect your Regulator - Rectifier unit first, and perhaps dirty or corroded electrical terminals. The procedure for checking these is too detailed to describe here, and you should consult your service manual for additional details.
5) Check the condition of your main circuit terminals.....they should be zestfully clean and un-corroded, or you're primed for a variety of problems......not only will your circuits not be getting full power out of your battery, but to add insult to injury, your charging system may think that the battery needs more juice, and so it starts cranking out amps like there's no tomorrow. It's pretty safe to say that neither of those two occurrences qualify as a Good Thing (tm), so...........start at the beginning, and inspect and clean (and then protect, like with di-electric grease or equivalent) all the [/b] terminal connection points[/b]:
* the positive battery post connection to the positive battery cable.
* the positive battery cable connection to the starter relay (or "solenoid").
* the main harness terminal connector from the starter relay.
* the main lead from the starter relay to the starter motor (both ends).
* the "main fuse" contacts inside the fusebox.
* the battery ground cable contacts at both the engine case and at the negative battery post (poor ground are just as bad as poor positive feeds; after all, it takes two to tango, or to complete a circuit, and electricity doesn't care where the restriction occurs).
Battery and Charging System Results:
Okay, now with all of the above out of the way, you should be able to determine whether you need a new battery, or not. There's no need to waste money on a replacement battery if it's not the root cause of your problems. If your battery is good, but your charging system or electrical system isn't, then spend your time and money on fixing the root causes of the problem........such efforts will also help prevent you from murdering your otherwise good battery.
But assuming that your battery is ready to be retired, the question then becomes, which battery?----as they come in a variety of types and price ranges (and, as with most things in life, the more you spend, typically, the better quality you'll get when it comes to a "commodity" product such as a battery).
Basically, motorcycle batteries are of two basic types, the flooded cell type (sometimes called a "wet cell" or "conventional" battery) and the AGM or "absorbed glass mat" type.
Your original-style, Yuasa-brand battery was a "conventional" type, and these are now available in both their original configuration, or in a high-performance version that can output more amperage than the standard style-----and this is typically a cost-effective upgrade.
AGM batteries feature cell separators made of fiberglass mats that minimize the movement of electrolyte (acid), and prevent spillage if tipped over on their side. The acid formulation in these also typically a bit stronger compared to flooded cell batteries, which accounts for their typically higher output. AGM batteries are of the permanently sealed, "maintenance-free" design, thus never requiring the further addition of water or acid.
The charging system of many modern motorcycles that come factory-equipped with an AGM type battery uses a regulator/rectifier that outputs a slightly higher voltage than a flooded cell battery requires. Using an AGM in almost any motorcycle will usually work well, while using a flooded cell battery in a bike designed for an AGM type will often result in overcharging and quick boiling of the electrolyte solution -- it isn't long before the battery is dry and possibly ruined. Of course, all of our XJ-series bikes came originally with a conventional wet ("flooded") type battery, so replacing them with the AGM types is not a problem or issue.
AGM type batteries are also more tolerant of sitting for long periods with minimum formation of lead sulfate (sulfation) on the plates. They can usually be charged at a slightly higher rate and in general provide better performance over the long haul. However, once AGM batteries are "dead"; they're dead, and cannot usually be brought back to life (even for a short amount of time) like a conventional battery can.
Finally, be aware that while AGM batteries are sometimes incorrectly called "gel cells batteries", a true "gel cell" type of battery is quite a different animal, and is actually not recommended for motorcycle use.
Battery FAQ's:
What is a conventional (or "wet" or "flooded") battery?:
These are the standard automotive type design battery, with individual push-in or screw-in battery cell access caps, a vented design, also referred to as a "lead-acid" design, and need the periodic addition of distilled water to "top up" the fluid level.
What is a "maintenance-free" battery?:
Maintenance-free batteries do not require the addition of water after their initial fill of their water/acid electrolytic solution. It means that it is a "sealed" battery, with no filler caps. Note that while conventional "wet" batteries may be available in a sealed, maintenance-free variety, AGM batteries are always of this sealed, maintenance-fee type.
What is a "high-performance" battery?:
Due to plate design and other factors, high-performance batteries have a denser charge ability and will output more amps for a longer period of time (this is the so-called *CCA rating number that is used to describe a battery) before full discharge. Although there have been some interesting technological "enhancements" to the basic conventional battery design over the years, almost all "high-performance" (meaning, higher-capacity) batteries rely on more lead material in their plates, resulting in a physically heavier battery. More lead = more money to manufacture and transport the battery, which is why these batteries cost more.
*NOTE: CCA (Cold Cranking Amperes) is the most popular industry rating and is a measurement of the current a fully charged battery can deliver for 30 seconds and maintain a voltage of 7.2 volts (12 volt battery) at a temperature of -18*-C (0* F).
What is an AGM battery?:
AGM is an abbreviation for "absorbed glass mat", and the liquid electrolyte contains high purity sulfuric acid and totally demineralized, deionized water (no phosphoric acid).
In this battery design, almost all of the battery sulphuric acid solution --- which, by the way, is typically also at a higher concentration level than of what is used in conventional "wet-cell" batteries --- is absorbed into glass mat separators which are sandwiched between the lead plates. It's a totally sealed and maintenance free design. There are no discharge tubes or fillers caps, which eliminates the need to maintain water levels and offers no concern about acid leaks on valuable parts and accessories.
AGM batteries offer the following advantages over conventional batteries because:
a) their sealed, maintenance-free design means you never have to worry about checking nor maintaining their fluid levels.
b) AGM batteries, unless physically damaged, will not leak or corrode your paint and chrome.
c) they have less internal resistance which offers more cranking amperage than wet batteries.
d) their lower self-discharge rate means they can sit for extended periods of time without constant monitoring. A conventional wet battery discharges 15% a month, whereas AGM batteries discharge only 2-3% a month.
e) a longer service life be expected from an AGM battery-----the main reason conventional wet batteries fail is due to water levels that are not properly monitored and maintained. Conventional batteries are also not very heat nor vibration resistant. AGM batteries are much more heat and vibration resistant than conventional batteries, and of course are maintenance-free, all of which contribute to their longer service life.
f) however, AGM batteries are more sensitive to both undercharge and overcharge conditions than conventional wet-cell, lead-acid batteries. They must be maintained correctly, and use a quality "smart" charger that does not stray too much, or too long, into the "overcharge" range of charging.
What is a gel-cell battery?:
Gel batteries contain a gelled electrolyte which is “Thixotropic”. This Thixotropic gelled electrolyte contains sulfuric acid, fumed silica, pure demineralized and deionized water, and a phosphoric acid. The electrolyte in Gel batteries does not flow like a normal liquid; it has the consistency and look of petroleum jelly.
AGM and Gel batteries compared:
Because of the physical properties of the Thixotropic gelled electrolyte in Gel batteries, Gel batteries tend to lose power faster than AGM batteries in temperatures below 32°F. AGM batteries, on the other hand, excel in high current and high power applications as well as extremely cold environments, making them ideal for cold weather riding or snowmobiling and also for running juice-drawing aftermarket accessories.
Another key difference between AGM and Gel batteries is depth of discharge. Gel batteries are more acid starved than AGM batteries, which better protects Gel batteries’ plates, making these types of batteries best suited for deep discharge applications. Although deep discharge is rarely necessary in powersports riding, however, and Gel batteries have drawbacks for powersports starting applications. Gel batteries typically have a higher price point, shorter life span and less size compatibility than their AGM counterparts.
In the spectrum of conventional lead acid, AGM and Gel batteries, AGM batteries typically offer the best starting power, durability and value for powersports applications such as motorcycles, ATVs and snowmobiles.
What is a lithium battery?:
Advantages Of Li-iron-phosphate (LiFePO4) Batteries:
Slow Discharge Rate: lithium-iron batteries have a huge advantage here because of its very slow discharge rate.
Weight (and thus size): Li-iron batteries have very low weights when compared to lead-acid batteries of the same specification. Because of this, they are preferred in racing bikes or in any case when the rider needs to achieve high performance from their bikes.
Design: LiFePO4 batteries can be fitted anywhere onto the bike, such as upside down or under seats, wherever the rider wants according to their needs.
Warranty: Li-iron batteries often have longer warranties than any other batteries. Some bike manufacturers even provide between three and five-year warranties if the battery is installed during the manufacturing process.
Disadvantages of Li-iron (LiFePO4) batteries:
Usage Limitations: LiFePO4 batteries cannot be used in conjunction with a total loss ignition system.
Charging System: the charging system used with the this type battery should be capable of maintaining a steady charging rate within the range of 13.6 to 14.4 volts. In the case of old or classic bikes, those that do not have such a charging capacity need extra upgrades. This can be costly and not always successful as it may, in certain cases, cause damage to the original parts.
Water: Li-iron batteries can handle only a small amount of water spray. They are not suitable when there is a significant danger of water ingress.
Discharge problem: if the lithium-iron battery is completely discharged, it will need to be charged fully before the next use using the charger supplied by the manufacturer. If it is not charged fully, the battery may sustain damage and its efficiency will start to degrade, reducing the life and use cycle of the battery.
Cold Temperatures: one of the most overlooked disadvantages of the Li-iron battery in relation to motorcycles is its performance in low temperatures. During the colder seasons, lithium batteries can take longer to work, the bike requiring some time to start. When this happens the rider must first warm up the engine by leaving it on for some time and then click on the starter. The Li-ion battery will only be able to supply proper voltage once it is heated to the required level.
Cost: lithium-iron batteries cost 30-200% more than a high-quality conventional or AGM battery, and their advantages must be weighed against their initial higher cost. Also, the quality of Lithium-Iron batteries varies somewhat dramatically depending on cost; the cheaper ones don’t have the internal safeguards and Battery Management Systems within their circuitry, which can lead to shortened life/failures.
Final Thoughts:
Our take is that unless you have extraordinary power or design demands, etc. then a good lead-acid battery (such as an permanently-sealed/maintenance-free AGM battery) is typically the better (and less-expensive) way to go:
https://advrider.com/f/threads/moto...el-wet-lithium-iron-phosphate-lifepo4.757934
What are the electrical specifications for an original battery?:
NOTE: CCA (Cold Cranking Amperes) is the most popular industry rating and is a measurement of the current a fully charged battery can deliver for 30 seconds and maintain a voltage of 7.2 volts (12 volt battery) at a temperature of -18*-C (0* F).
all XJ550 and XJ650 models:
Capacity: 12ah
Charging rate: 10 hours @ 1.2A
CCA's: 113
all XJ700, XJ750, and XJ900RK models:
Capacity: 14ah
Charging rate: 10 hours @ 1.4A
CCA's: approximately 130
XJ1100 and XS1100 models:
Capacity: 20ah
Charging rate: 10 hours @ 2.0A
CCA's: 260
How should a battery be maintained?:
Good battery maintenance allows you to get the maximum power and life from your battery:
a) always keep the acid level between lower and upper lines on front side of the container (for conventional type batteries that are not sealed).
b) do not let the battery remain in a discharged condition for any length of time. Discover and remedy the cause of such a condition immediately.
c) when a bike is stored for over 30 days at a time, use an automatic battery charger to maintain a proper storage charge.
d) keep the top of the battery case clean, dry, and free of dirt or moisture.
e) clean the battery terminals to prevent corrosion, and treat them to some anti-corrosion spray or coat their exposed areas with di-electric grease. Do not over-tighten the terminal cinch bolts!
f) inspect the battery vent tube regularly, ensuring that it is not bent, twisted or clogged, especially at the bottom of the tube, where it discharges towards the ground......this is the most common place where the tube will get clogged via road debris, etc.
g) protect the battery from strong impacts or shocks.
How long will my new battery live?:
Regardless of battery type or manufacture, you can expect a properly activated, and properly maintained battery (meaning it's neither overcharged nor overly or repeatedly allowed to become fully discharged) to give you 2-4 solid years of life.
Heat is the big enemy of motorcycle batteries----they'll last much longer in a cool climate than a hot one. The self-discharge rate of a battery can run as high as 3% a day in hot weather with a flooded cell battery to about 1% or less per day with an AGM type. Overcharging a battery also overheats a battery---a double whammy! Make sure your charging system is in good order to get the maximum life from your battery.
Constant, repeated complete discharges of a battery will also reduce their lifespan. There's only so many times you can "drain the well" before a battery electrically gives up the ghost.
What are some of the best ways to kill a battery?:
a) Let a discharged battery freeze. Fully discharged batteries freeze at about +25-F, or just below the freezing temperature of water. Fully charged batteries freeze at about 75-F below zero. 'Nuff said........
b) Let a battery overheat.
c) Overcharge the battery........either via the use of an incorrect (or poor quality or defective battery charger), a charging system regulator gone bad, or highly corroded (high resistance) wiring harness connections within the system.
d) "Quick-charge" the battery using an incorrect style battery charger.
e) Allow the fluid level (for wet or conventional batteries) to get too low. This exposes the plates to air, which cause the plates to "sulfate", which leads to increased electrical resistance and a drop in power output.
f) Run a battery down into deep-discharge. Each full discharge event causes sulfate build-up on the lead plates. Do this enough times.....like when your charging system isn't outputting properly........and you'll kill a battery pretty quickly.
g) On conventional batteries, do not use regular tap water to fill or re-fill the battery. Tap water contains minerals and metals that will shorten the life of a battery. Always use distilled or de-mineralized water to fill a battery.
What about my original battery fluid level sensor?:
Some original models with the "computer" dashboard monitor system (1982 XJ750 Maxim, 1981-83 XJ750 Seca, and XJ1100 models) had a low-battery-fluid warning light on the dash, triggered by a fluid-level sensor which replaced one of the battery cell screw-in caps. If the fluid level in that battery cell was too low to trigger the sensor, the circuit in the computer dash warning system would read that as a low-voltage condition and would then illuminate the warning light.
So of course, the first issue in regards to these sensors is: if the light is on, first check your fluid level!
But other issues arise: it could be that the tip of the sensor has become dirty, or encrusted with deposits, in which case even if the fluid level is fine, it will still sense a low-voltage condition. This can be remedied with a gentle cleaning of the sensor tip (steel wool, brass bristle brush, etc.).
Also, the sensor reads voltage, and without enough voltage to trigger the computer system, the light illuminates. The wire path from the sensor goes through your ignition switch and if this switch has electrically "dirty" internal contacts, then that can add enough resistance to cut the voltage signal enough to trigger the dash "low Batt" warning light or display, even though the sensor is fine and the fluid level is okay! So: remove the ignition switch, and its bottom plate, and clean the copper contacts inside the ignition switch.
Finally: a few issues arise with replacement batteries in regards to the use of sensors:
a) some batteries are designed to allow you to re-use your original sensor (we also offer a replacement sensor in case your original is missing or damaged). These conventional-style batteries will feature screw-in caps and your original sensor will screw right in place (by the way, the sensor must be installed in the 4th cell over from the negative post or it will not work correctly and may damage your dash computer!).
b) but some aftermarket batteries, even though they have screw-in caps, have a different "plate depth" internally, and even though the original sensor will screw into the cell port, the sensor tip will be too deep and contact the lead plates in the battery which will cause battery, sensor, and dash computer damage! Thus you must be careful with aftermarket batteries, and measure the depth of the cell, and if it's shorter than that of an original battery, you must use plastic spacer shims (washers) to space an original sensor "upwards" to the proper depth for such batteries, or carefully trim the sensor tip shorter so that it does not ever contact the internal plates.
c) other aftermarket batteries will have push-in rather than screw-in caps. An original sensor will not fit into these batteries unless that one cell port is "threaded" to accept the sensor. This can be best accomplished by gently screwing into the cell port a proper sized and thread steel bolt, and thus "cutting threads" of the proper size into that cell port opening. Now your original screw-in sensor can be properly installed; however, the same warnings as in issue "b" above (in regards to the depth of the cell) must be observed and remedied, if necessary. Of course, make sure that as you cut these new threads into the battery case, that any plastic "shavings" that are created by this threading process do not get into (or are removed) the battery cell.
d) some of the replacement Yuasa batteries that we offer come with a replacement sensor.......in which case, you discard (or save) your original sensor and just hook up your sensor wire lead to this new sensor.
e) some aftermarket batteries.....such as the replacement "maintenance-free" (sealed) and all AGM batteries......have no "cell caps" and thus are not going to accept a sensor, at all. This present a problem, since the lack of voltage to the dash computer makes it think that there is a battery problem, and the red warning light or display message is always on or blinking at you. Although you can "reset" this annoyance away, there are two other solutions available to you in order to disable or bypass this function:
i) on models that use a warning light, you can simply remove the bulb from your dash! No more "warning" of a low battery fluid condition (except on the LCD display screen), but no more annoying blinking light, either.
ii) on all models, you can install our HCP9982 sensor bypass wire that duplicates the function of the original sensor.
What are the best battery myths?:
a) that putting a battery on a cement floor will cause it to discharge. This may have been true a long time ago, when the battery case was made of a rubber material, which would develop hairline cracks and thus allow moisture to permeate into the case, opening up an electrical circuit which would quickly discharge a battery. Modern batteries use molded plastic cases that do not suffer from such a fate.
b) that bringing a battery inside during the winter will prolong its life. Batteries produce electricity via a chemical reaction, and the chemical reaction results in the production of sulfate deposits on the lead plates within the battery, and these sulfate deposits act as electrical insulators----thus reducing the power output and the overall life of the battery. These chemical reactions slow down dramatically with lower temperatures. As long as your battery does not freeze, the lower the temperature, the less the amount of chemical reactions taking place, thus prolonging the life of the battery!
Remember, heat is one of the things that wears out batteries, because they speed up the amount and intensity of these chemical reactions that creates the sulfate deposition on the lead plates.....and those deposits are what really "kills" the battery.
By the way, the main reason why your car or bike cranks over so slowly during winter is not due to "thicker oil" (multi-viscosity oils took care of that issue a long time ago), but because of the decreased chemical reactions (meaning less electrical output generation) within the battery due to those lower temperatures.
Can I jump-start my dead motorcycle battery from a car battery?:
Yes, BUT.................
a) you need to make sure that you are using the proper gauge jumper cables.
b) hook the jumper cables up incorrectly (+ to -) and if you're lucky, you'll just burn up your TCI unit. If you're unlucky, you'll blow up your battery, your bike, or yourself.
c) make sure that your key switch and all electrical power drains are OFF before you hook up the jumper cables.
d) the best sequence of battery connection is to hook up both jumper cables onto the dead battery first, and then connect the positive lead to the good battery, and finally the negative lead to the good battery (or a good ground on the donor battery frame, etc.).
Your quest for more battery knowledge may still remains unsatisfied; if so, a great battery tutorial can be found at:
http://www.batteryfaq.org
and
http://www.dansmc.com/batteries.htm
BATTERIES:
All of the following batteries are high-quality, the correct size to fit into your battery box, and have the proper terminal orientations for your bike.
All batteries can be shipped only with the USA, and can be shipped either via ground or air delivery. However, due to the weight of the batteries, the free or reduced shipping discounts do not apply to these items!
NOTE: all batteries come with cable terminal attaching bolts and nuts; all non-sealed batteries have the overflow tube included; and all batteries come with charging instructions which must be followed exactly in order to not damage the battery during initial charging! AGM batteries come charged, but you should check the voltage and slowly (meaning with the use of a "trickle charger") bring the battery back to full charge before first use.....doing otherwise will void any manufacturer's warranty!
NOTE: on all non-sealed ("wet" or "conventional" style batteries) always be sure to remove the small red seal from the overflow vent tube when installing the battery. Never put this red tube back on to the battery after it is activated. Gases built up in a battery that is not allowed to vent can cause serious damage, and possible serious injury, if the battery bursts.
for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and XJ650 models:
NOTE: also fits all of the following models: 1970-72 XS1, XS1B, and XS2 models; 1977-83 XS400 all models, 1980-82 SR250, 1987 SRX250, 1911 XS360, 1980 SR500, 1983-84 XV500, 1973 TX650, 1983 XS650, and 1983 XV920MK Midnight Virago models.
HCP1425 OEM original style STANDARD-PERFORMANCE WET-CELL BATTERY, genuine Yuasa brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 12 amp-hours, 113 CCA rating.
$ 59.95
HCP28140 Aftermarket original style STANDARD-PERFORMANCE WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 12 amp-hours, 113 CCA rating.
$ 47.95
HCP10455 OEM replacement style HI-PERFORMANCE WET-CELL BATTERY, genuine Yuasa Yumicron brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 12 amp-hours, 165 CCA rating.
$ 72.95
HCP28141 Aftermarket replacement style HI-PERFORMANCE WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 12 amp-hours, 135 CCA rating.
$ 59.95
HCP28143 Aftermarket AGM BATTERY. This is an Absorbed Glass Mat type battery and is already filled with the acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. Comes with a set of terminal installation bolts and nuts. 12 volts, 12 amp-hours, 120 CCA rating.
$ discontinued
HCP28142 Aftermarket HIGH-PERFORMANCE AGM BATTERY. This is an Absorbed Glass Mat type battery and is already filled with the acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. Comes with a set of terminal installation bolts and nuts. 12 volts, 15 amp-hours, 160 CCA rating.
$ 89.95
SPECIAL!: purchase any of the batteries above and you can purchase the HCP28172 Smart Charger for just $ 29.95 (regularly $ 39.95). This is an exceptional deal!
for all 1992-98 XJ600 Seca II and 1990-95 XT600 models:
HCP27716 OEM original style STANDARD-PERFORMANCE WET-CELL BATTERY, genuine Yuasa brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 12 amp-hours, 113 CCA rating.
$ 89.95
HCP20121 Aftermarket original style STANDARD-PERFORMANCE BATTERY. This is a maintenance-free battery. Standard-performance design.
$ discontinued
HCP28144 Aftermarket AGM BATTERY. This is an Absorbed Glass Mat type battery and is already filled with the acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. 12 volts, 8 amp-hours, 90 CCA rating.
$ 59.95
HCP28145 Aftermarket HIGH-PERFORMANCE AGM BATTERY. This is an Absorbed Glass Mat style battery and is already filled with the acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. 12 volts, 8 amp-hours, 160 CCA rating.
$ 79.95
SPECIAL!: purchase any of the batteries above and you can purchase the HCP28172 Smart Charger for just $ 29.95 (regularly $ 39.95). This is an exceptional deal!
for all XJ650 Police models, all XJ700 models, 1983 XJ750 Maxim and Midnight Maxim, XJ750 Police models, XJ750-X models, and XJ900RK, RL, and N/FN models:
NOTE: these batteries will also fit all of the following models if the battery sensor system is disabled using our HCP9982 battery sensor bypass device: 1982 XJ750 Maxim and 1981-83 XJ750 Seca models. If you want a battery that comes with or accommodates the original low-fluid level sensor, then see battery HCP10457 in the next section below.
HCP9982 Aftermarket battery fluid level SENSOR BY-PASS / REPLACEMENT, for all XJ650 Police, 1981-83 XJ750 Seca, 1982 XJ750 Maxim, XJ750 Euro (11M) models, XJ750 Police, 1982 XV920J Virago, and XJ1100 models. Completely replaces the original sensor with this bypass sub-harness. Typically needed when using a replacement battery that does not accept an original style screw-in sensor. Tuned resistance level allows the display and warning light to still warn you of a low battery voltage condition, but no longer tells you anything about the fluid level (of course, a low voltage condition could be caused by a low fluid level, among other things). Simple plug-in installation to the original main harness sensor lead wire; contains an extra male bullet terminal for the main harness wire, in case someone cut it off in the distant past (a common problem with previous owners!). You can review the installation procedure for this product at: http://www.xj4ever.com/HCP14180 battery sensor bypass.pdf
$ 19.95
NOTE: these batteries also fit all of the following models: 1973-74 TX500, 1974 TX650, 1982 XT550, 1982-83 XZ550 RJ/RK Vision, 1975-78 XS500, 1975-83 XS650 all models, 1977-79 XS750, 1980-81 XS850, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 and 1988 FZ750, 1987 FZR750R, 1987-90 FZR1000, 1984-85 FJ1100, and 1986-90 FJ1200 models.
NOTE: some replacement batteries for these models are just slightly taller than the original batteries, and because of the cramped spaces in the battery box area, beware of the positive or negative terminal contacting the bottom of a frame tube. Such a situation is extremely dangerous and can lead to fire, explosion, injury, or death! You should always observe whether such a condition exists in these models, and if so, take preventative steps to prevent any contact of the battery terminals with the bike's frame! (especially when the bike is in motion, going over bumps, etc.). One possible solution is to WRAP THE FRAME RAIL WITH A PIECE OF PLASTIC TUBE, HOSE, OR MULTIPLE LAYERS OF ELECTRICAL TAPE DIRECTLY ABOVE THE BATTERY TERMINALS TO PREVENT ANY DIRECT CONTACT FROM OCCURRING!!
HCP10409 OEM original style STANDARD-PERFORMANCE WET-CELL BATTERY, genuine Yuasa brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 14 amp-hours, 128 CCA rating.
$ discontinued
HCP28146 Aftermarket original style STANDARD-PERFORMANCE WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 14 amp-hours, 128 CCA rating.
$ 47.95
HCP1427 OEM replacement style HI-PERFORMANCE WET-CELL BATTERY, genuine Yuasa Yumicron brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow screw-in style filler caps, terminal bolts and nuts, and overflow tubing. No fluid level sensor is included, and please note that the plate depth in this battery will REQUIRE modification (shortening) of an original screw-in sensor in order to avoid "bottoming" of the sensor probe onto the cell plate. 12 volts, 14 amp-hours, 190 CCA rating.
$ 69.95
HCP28147 Aftermarket replacement style HI-PERFORMANCE WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow screw-in style filler caps, terminal bolts and nuts, and overflow tubing. No fluid level sensor is included, and please note that the plate depth in this battery will REQUIRE modification (shortening) of an original screw-in sensor in order to avoid "bottoming" of the sensor probe onto the cell plate. 12 volts, 14 amp-hours, 160 CCA rating.
$ 59.95
HCP28149 Aftermarket AGM BATTERY. This is an Absorbed Glass Mat type battery and is already filled with an acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor. Comes with a set of terminal installation bolts and nuts. 12 volts, 14 amp-hours, 160 CCA rating.
$ 79.95
HCP28150 Aftermarket HIGH-PERFORMANCE AGM BATTERY. This is an Absorbed Glass Mat type battery and is already filled with an acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor). NOTE: this battery is approximately 2mm taller than an original battery, and may require some slight modification to your original battery box for terminal attachment clearance on some models. Comes with a set of terminal installation bolts and nuts. 12 volts, 16.5 amp-hours, 210 CCA rating.
$ 99.95
SPECIAL!: purchase any of the batteries above and you can purchase the HCP28172 Smart Charger for just $ 29.95 (regularly $ 39.95). This is an exceptional deal!
for all 1982 XJ750 Maxim and 1981-83 XJ750 Seca models:
NOTE: the 1982 XJ750 Maxim and all 1981-83 XJ750 Seca models used a battery sensor device in the 4th cell over from the negative terminal. Do not place the sensor in any other cell, or it could damage the microprocessor in your dash!
NOTE: the following battery comes with a low-fluid level sensor already installed in the battery. Bikes that originally used these sensors can also use any of the non-sensor style batteries (listed in the section above) but you will either have to re-use your factory sensor (on battery HCP1427 above) or disable or bypass the factory low-fluid circuit if using the HCP10456 maintenance-free or the HCP10402 agm style batteries listed above. Our HCP9982 battery sensor by-pass allows you to properly eliminate the sensor device from the system.
NOTE: some replacement batteries for these models are just slightly taller than the original batteries, and because of the cramped spaces in this area, beware of the positive or negative terminal contacting the bottom of the frame rail. Such a situation is extremely dangerous and can lead to fire, explosion, injury, or death! You should always observe whether such a condition exists in these models, and if so, take preventative steps to prevent any contact of the battery terminals with the bike's frame! (especially when the bike is in motion, going over bumps, etc.). One possible solution is to WRAP THE FRAME RAIL WITH A PIECE OF PLASTIC TUBE, HOSE, OR MULTIPLE LAYERS OF ELECTRICAL TAPE DIRECTLY ABOVE THE BATTERY TERMINALS TO PREVENT ANY DIRECT CONTACT FROM OCCURRING!!
HCP10457 OEM replacement style HI-PERFORMANCE WET-CELL BATTERY, genuine Yuasa Yumicron brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow screw-in style filler caps, terminal bolts and nuts, and overflow tubing. A replacement style fluid level sensor IS included. 12 volts, 14 amp-hours, 190 CCA rating.
$ 159.95
SPECIAL!: purchase any of the batteries above and you can purchase the HCP28172 Smart Charger for just $ 29.95 (regularly $ 39.95). This is an exceptional deal!
for all XJ1100 and XS1100 models:
NOTE: the XJ1100 Maxim and 1983 XV920MK Midnight Virago models used a battery low-fluid level sensor device. The HCP10458 and HCP28153 batteries listed below are the only batteries that comes with a sensor, and no other batteries comes with nor can accept a fluid level sensor. For these models, you can use any of the non-sensor style batteries but you must bypass the factory low-fluid level circuit. Our HCP9982 battery sensor by-pass device allows you to properly eliminate the sensor device from the system.
HCP9982 Aftermarket battery fluid level SENSOR BY-PASS / REPLACEMENT, for all XJ650 Police, 1981-83 XJ750 Seca, 1982 XJ750 Maxim, XJ750 Euro (11M) models, XJ750 Police, 1982 XV920J Virago, and XJ1100 models. Completely replaces the original sensor with this bypass sub-harness. Typically needed when using a replacement battery that does not accept an original style screw-in sensor. Tuned resistance level allows the display and warning light to still warn you of a low battery voltage condition, but no longer tells you anything about the fluid level (of course, a low voltage condition could be caused by a low fluid level, among other things). Simple plug-in installation to the original main harness sensor lead wire; contains an extra male bullet terminal for the main harness wire, in case someone cut it off in the distant past (a common problem with previous owners!). You can review the installation procedure for this product at: http://www.xj4ever.com/HCP14180 battery sensor bypass.pdf
$ 19.95
NOTE: these batteries also fit all of the following models: 1981-83 XV920 Virago models (see note above about sensor use on 1983 XV920MK model), 1984-85 XV1000 Virago, 1986-99 XV1100 Virago, 1983-85 XVZ1200, 1986-88 XVZ13, 1988-89 XVZ13 Venture Royal, and 1990-93 XVZ13 models.
HCP10583 OEM original style STANDARD-PERFORMANCE WET-CELL BATTERY, genuine Yuasa brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. 12 volts, 20 amp-hours, 220 CCA rating.
$ discontinued
HCP28151 Aftermarket original style STANDARD-PERFORMANCE WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Standard-performance with removable filler caps, terminal bolts and nuts, and overflow tubing. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor). 12 volts, 20 amp-hours, 220 CCA rating.
$ 79.95
HCP28152 Aftermarket original style STANDARD-PERFORMANCE, LOW-MAINTENANCE, WET-CELL BATTERY. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Re-absorbtion technology controls fluid evaporation, resulting in much reduced frequency to check and re-fill battery with water. Standard-performance with removable filler caps, terminal bolts and nuts, and overflow tubing. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor). 12 volts, 20 amp-hours, 220 CCA rating.
$ 119.95
HCP10458 OEM replacement style HI-PERFORMANCE WET-CELL BATTERY, genuine Yuasa Yumicron brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. Fluid level sensor and adapter harness IS included. 12 volts, 20 amp-hours, 260 CCA rating.
$ 139.95
HCP28153 Aftermarket replacement style HI-PERFORMANCE WET-CELL BATTERY, genuine Yuasa Yumicron brand. This is a "conventional" or "wet/flooded" style battery and must be filled with an acid-and-water mix before initial charging. The acid is not included and must be purchased by you at a local automotive parts store. Higher-performance designs features 30% greater cold-cranking amp capacity than standard (original) battery, and comes with the removable yellow push-in style filler caps, terminal bolts and nuts, and overflow tubing. Fluid level sensor and adapter harness IS included. 12 volts, 20 amp-hours, 220 CCA rating.
$ 119.95
HCP28154 Aftermarket AGM BATTERY. This is an Absorbed Glass Mat style battery and is already filled with an acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor). Comes with a set of terminal installation bolts and nuts. 12 volts, 20 amp-hours, 230 CCA.
$ 99.95
HCP28155 Aftermarket HIGH-PERFORMANCE AGM BATTERY. This is an Absorbed Glass Mat style battery and is already filled with an acid-and-water mix and fully sealed, making it maintenance free for the life of the battery. No fluid level sensor is included nor can be used (you will have to disable or bypass your low-fluid-sensor). Comes with a set of terminal installation bolts and nuts. 12 volts, 25 amp-hours, 300 CCA.
$ 119.95
SPECIAL!: purchase any of the batteries above and you can purchase the HCP28172 Smart Charger for just $ 29.95 (regularly $ 39.95). This is an exceptional deal!
Battery Tools, Testers, Chargers, and Hardware:
HCP10448 Aftermarket battery testing HYDROMETER. This is a real hydrometer, not the cheapo 4-dollar special you usually see at the auto parts store. It measure the specific gravity of the electrolytic fluid, which is the proper way to test its condition. Those little "floating balls" testers are barely worth the plastic that they're made of! This professional hydrometer gives you temperature-adjusted specific gravity readings, which is the only accurate method of measurement. And yes, you can use these on your car or tractor or boat battery, too........
$ 12.95
HCP10542 Aftermarket battery testing MINI-HYDROMETER. This is a cheapy, "floating ball" style hydrometer, but it's small size makes it easier to use on motorcycle batteries. It's better than not having one at all! And yes, you can use these on your car or tractor or boat battery, too........
$ 7.95
fbc3) Aftermarket automatic BATTERY CHARGERS. A fully automatic battery charger is the best type to use to provide "trickle charge" to deep-cycle batteries, as it prevents the overcharge conditions that dramatically reduce the life of a battery.
HCP9962 Aftermarket automatic BATTERY CHARGER, standard bench-top style. Features that a 1.5A charger rate can be used to re-charge a dead battery quickly or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup protection, LED power-on/charging/charged indicator lights, CSA-certified, and comes with both 50A standard spring clamps or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 59.95
HCP28172 Aftermarket fully automatic BATTERY MAINTAINER-CHARGER. This compact wall-transformer style 6V and 12V charger features the latest solid-state, intelligent technology that allows quick, safe, and efficient charging of all battery types: conventional lead acid, maintenance-free lead acid, marine deep-cycle, AGM, gel-cell, and even lithium-ion. Features include: will safely charge even a fully dead battery (one that reads 0 volts), an automatic “de-sulphation” mode that can rescue and extend the life of older batteries, a thermal compensation sensor to prevent under- or over-charging, short-circuit protection, open-circuit protection, over-heat protection, over-charge protection, reverse-hookup protection, and spark protection. Can be hooked directly to the battery terminals with included ring terminals (a water-proof disconnect port is built into the 9-foot long lead wires), or you can use it with the included thin, “needle-nose” style clamps. Automatically changes from full-charge to float-mode monitoring for extended battery life and no worries about over-charging…..you can actually leave this charger hooked up to your battery 24/7 for as long as you want (like, all winter long……..) without risking battery damage (in fact, for all conventional lead-acid batteries, you should attempt to maintain it at 100% charge to maximize the battery life). Works on 110-240V AC current, 1-amp (max.15W) charging current, water-proof housing, 3-year warranty. This is most affordable and best “home-use” battery charger on the market/
$ 39.95
HCP28173 Aftermarket fully automatic BATTERY SUPER-CHARGER, all the same features as the HCP28172 above, but this charger feature more power output (2A, max. 30W charging current) and is a “mini-tabletop” design…..about 5.5” x 2.5”….no bigger than a typical computer mouse!
$ 69.95
HCP10449 Aftermarket automatic BATTERY CHARGER, compact wall-transformer style. Features that a 1.3A "pulse-mode" charger that can be used to re-charge a dead battery or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 79.95
HCP10451 Aftermarket automatic BATTERY MAINTENANCE CHARGER, compact wall-transformer style. Features that a 800ma (0.8A) charger rate, perfect for maintaining a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup and short-circuit protection, LED power-on/charging/charged indicator lights, waterproof, and comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. No bigger than a typical computer "mouse"! Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 59.95
HCP10452 Aftermarket battery charger EXTENSION CABLE, 12-foot length. Don't want to bring your bike over to your charger? Then this set of 12-foot long charger-to-battery leads extender cable allows you to leave the battery charger close to a wall outlet, and extend the power leads to wherever your bike is located! Quick-connect feature allows plug-and-play installation with all of the above chargers. Very convenient.
$ 19.95
et3) Aftermarket motorcycle-sized BATTERY JUMPER CABLES. Small sized end clips more easily reach into the cramped areas where your battery lives, making it somewhat easier to jump-start a dead bike. NOTE: NEVER attach jumper cables to your battery unless your ignition key is OFF......or your risk frying a lot of expensive electrical components!
HCP1608 Aftermarket 5-foot long standard duty JUMPER CABLES, with alligator clip ends.
$ 29.95
Battery Sensors:
eb1) OEM Battery LOW FLUID SENSOR---this one battery cap is used in the #3 cell from the positive terminal (or, if you prefer, the 4th cell from the negative terminal) and reports a low battery fluid (water) condition to the dash warning lights. Without this sensor present, or if it malfunctions, the "low battery" warning light will always be lit. With harness pigtail. NOTE: these sensors are the correct depth to fit the original Yuasa batteries. Other manufacture batteries may require a shorter sensor depth, and you must measure and then trim the sensor tip shorter (if necessary) to insure that the tip does not bottom out in the battery! If your battery does not have screw-in style cell caps, you will have to use our thread-cutting bolt, such as our HCP10474, to forcibly "cut" threads in the proper cell to allow the original style threaded sensor to screw in.
NOTE: this sensor housing and its probe tip must be shortened by about 12mm to fit into the current "stock replacement" Yuasa battery HCP1427 listed above. Additionally, you also need to use an additional rubber shimming washer HCP10581 (listed below) to gain the total additional clearance in order for this sensor to work in the HCP1427 battery.
Of course, these sensors will not fit nor work in any type of AGM or "maintenance-free" style sealed batteries.
HCP1449 OEM Battery LOW FLUID SENSOR, for all XJ750 Seca, 1982 XJ750 Maxim, and XJ1100 models, blue, screw-in type, with wire lead:
$ 48.95
HCP10581 Aftermarket battery sensor SHIMMING WASHER, for use with the HCP1449 fluid sensor when installing it into the replacement HCP1427 Yuasa battery.
$ 1.00
HCP10474 Aftermarket battery sensor THREAD-CUTTING BOLT, allows for the use of the original screw-in HCP1449 fluid sensor when installing it into an aftermarket wet-cell battery that do not have threaded cell port holes.
$ 1.95
HCP9982 Aftermarket battery fluid level SENSOR BY-PASS / REPLACEMENT, for all XJ650 Police, 1981-83 XJ750 Seca, 1982 XJ750 Maxim, XJ750 Euro (11M) models, XJ750 Police, 1982 XV920J Virago, and XJ1100 models. Completely replaces the original sensor with this bypass sub-harness. Typically needed when using a replacement battery that does not accept an original style screw-in sensor. Tuned resistance level allows the display and warning light to still warn you of a low battery voltage condition, but no longer tells you anything about the fluid level (of course, a low voltage condition could be caused by a low fluid level, among other things). Simple plug-in installation to the original main harness sensor lead wire; contains an extra male bullet terminal for the main harness wire, in case someone cut it off in the distant past (a common problem with previous owners!). You can review the installation procedure for this product at: http://www.xj4ever.com/HCP14180 battery sensor bypass.pdf
$ 19.95
Electrical System Tools:
et1) Aftermarket electrical test MULTIMETERS, the most useful tool you'll ever own for working on electrical systems. High quality test instruments make your life easier, and give you the accurate measurements needed to diagnose and track down electrical system issues.
http://nadp.sws.uiuc.edu/cal/PDF/MulltimeterUse.pdf
https://learn.sparkfun.com/tutorials/how-to-use-a-multimeter?_ga=1.238289411.262114863.1436923213
http://www.masonmonitoring.com/pdf/support/UsingMultimeter.pdf
https://learn.sparkfun.com/tutorials/how-to-read-a-schematic
http://www.autoshop101.com/forms/elec12.pdf
HCP7135 Aftermarket ANALOG (moving needle) MULTIMETER, more accurate than digital meters but a bit less user-friendly. These 6-function meters measure DC voltages (0-100), AC voltages (0-750), Resistance (0-10 megaohms), DC Current (0-10A), and has a small battery testing dial. NOTE: this multimeter does NOT have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event).
$ 79.95
HCP7136 Aftermarket DIGITAL (numerical LCD display) MULTIMETER, less accurate than analog meters but a bit more user-friendly. This 5-function meters measure DC voltages (0-1000), AC voltages (0-700), Resistance (0-2 megaohms), DC Current (0-10A), and Diode Checking. NOTE: this multimeter DOES have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event). Accuracy: DC voltage +/- 0.7%, AC voltage +/- 1.2%, DC current +/- 1%, Resistance +/-1%.
$ 69.95
eb4) OEM original battery DRAIN - OVERFLOW HOSE, fits onto the drain nipple on the battery and routes battery fluid and gases underneath the bike.
HCP16153 OEM black battery DRAIN - OVERFLOW HOSE, fits all XJ models, trim to proper length as described below.
$ 6.95
Drain hose routing and length:
- on 550 all models the original hose is approximately 23" long and is routed out of the battery vent, slides down the inside of the frame rail, and goes thru a hole in the "ear" of the welded-to-the-frame brake light switch bracket. From there, it routes forward of the swingarm, then snakes down rearward and forward again against the back of the motor and passes in front of the centerstand cross-tube.
- on 650 (except Turbo) models, all 1981-83 XJ750 models, and all XJ900 models, the original hose is approximately 24" long and is routed out of the battery vent, through the battery box bottom access hole, and then forward of the lower frame cross brace, and then through a welded clamp at the center of the frame cross tube.
- on XJ650 Turbo models, the original hose is approximately 24" long and is routed out of the battery vent, then straight down thru battery box, then behind the footpeg, outside of the frame tube, and the through a welded clamp on the centerstand mounting bracket.
- on all XJ700 and XJ750-X models, the original hose is approximately 18" long and is routed out of the battery vent, through the tool caddy bottom hole and then forward of the frame cross brace, through a welded clamp on frame cross tube, where airbox drain tube also lives.
- on XJ1100 all the original hose is approximately 22" long and is routed out of the battery vent, and comes straight down the side of the battery and then turns 90-degrees towards the center of the bike. There are two clamps that guide the hose along the forward edge of the battery tray, and then in the center of the bike, the hose takes a 90-degree turn straight down, where it goes thru a welded-on clip on the front of the lower frame cross-tube and then hangs down, towards the ground.
Battery Warning and Maintenance ID Decals:
These decals are typically found attached inside the frame side cover panels (or, on some models, attached to the bottom of the seat pan) and illustrate proper battery vent hose installation and routing, battery sensor warnings, and battery removal information.
HCP15127 Aftermarket battery VENT TUBE WARNING, white decal with orange wording and illustration warns the user to remove the vent tube block-off before battery installation. This small paper decal is used on all models and it is typically located on the top of the battery case next to the vent hose opening.
$ 6.95
HCP8122 Aftermarket battery REMOVAL/INSTALLATION PROCEDURE DECAL, silver decal with black wording cautions the user on proper battery removal and installation. This rectangular foil decal (about 2-1/2” wide x 1-5/8” tall) is used on all XJ550 models and is typically located inside the left side frame cover.
$ 8.95
HCP8124 Aftermarket CAUTION BATTERY REMOVAL/INSTALLATION PROCEDURE DECAL. This small, rectangular (2-1/2” wide x 1-1/4” tall) clean vinyl decal has white lettering and cautions the user on proper battery removal and installation. Used on all XJ650 models, XJ700, XJ750-X, some XJ750 Seca models, and all 1983-89 XJ900 models. It is located inside the right side frame cover (all models except XJ650 Turbo) or on the seat pan (XJ650 Turbo) and inside the left frame cover on XJ900 models. NOTE: XJ750 Seca models may have used this decal or the HCP8123 decal below, as we have seen examples of both types on original covers.
$ 8.95
HCP8123 Aftermarket CAUTION BATTERY REMOVAL/INSTALLATION PROCEDURE DECAL. This small, rectangular (2-1/2” wide x 1-1/4” tall) clean vinyl decal has white lettering and cautions the user on proper battery removal and installation. Used on all 1981-84 XJ750 Maxim models, some XJ750 Seca models, and XJ1100 models. It is located inside the right side frame cover on XJ750 models, and inside the left cover on XJ1100 models. NOTE: XJ750 Seca models may have used this decal or the HCP8124 decal above, as we have seen examples of both types on original covers.
$ 9.95
HCP8119 Aftermarket battery SENSOR INSTALLATION DECAL, silver decal with black wording and graphics cautions the user on proper battery sensor position. This foil decal is used on all 1982-83 XJ650 Turbo models (on the seat pan), inside the right frame cover on 1981-83 XJ750 Seca models, and inside the left frame cover on XJ1100 models.
$ 11.95
HCP15457 Aftermarket battery SENSOR INSTALLATION/DRAIN HOSE ROUTING DECAL, large silver decal with black wording and graphics cautions the user on proper battery sensor position and battery drain hose routing. This foil decal is used on all 1982 XJ750 Maxim models inside the right frame cover.
$ 14.95
HCP8152 Aftermarket battery DRAIN HOSE ROUTING DECAL, silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ550 models inside the left frame cover.
$ 12.95
HCP8151 Aftermarket battery DRAIN HOSE ROUTING DECAL, large silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ650 (except Turbo) models and 1981-83 XJ750 Seca inside the right frame cover.
$ 11.95
HCP15134 Aftermarket battery DRAIN HOSE ROUTING DECAL, large silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ650 Turbo models on the seat pan.
$ 11.95
HCP15124 Aftermarket battery DRAIN HOSE ROUTING DECAL, silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ700 and XJ750-X models inside the right frame cover.
$ 11.95
HCP15126 Aftermarket battery DRAIN HOSE ROUTING DECAL, large silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ900 models inside the leftt frame cover.
$ 11.95
HCP15125 Aftermarket battery DRAIN HOSE ROUTING DECAL, silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ1100 models inside the right frame cover.
$ 11.95
HCP15125 Aftermarket battery DRAIN HOSE ROUTING DECAL, silver decal with black wording and graphics illustrate the proper battery breather "pipe" (hose) routing. This foil decal is used on all XJ1100 models inside the right frame cover.
$ 11.95
Battery System Chemicals:
NOTE: it’s important to understand the difference between the two types of greases used with electrical connectors. Di-electric grease acts as an electrical insulator: it does not allow current to flow through it easily, and is basically used to “waterproof” a connector assembly. Although it is an insulator, the act of engaging two electrical connectors together (i.e. pushing a male connector into a female connector) will push away the grease on the metal-to-metal contact portion of the terminals, so those remain electrically conductive (good) while also insulating all the other surfaces against moisture and oxygen intrusion (very good). This insulating property of di-electric grease makes it great for use in connector shells, etc. as terminal corrosion is one of the greatest contributors to electrical system problems in vehicles (especially older ones)……this is why most modern vehicles use “sealed” connector shells (the most popular is the Delphi Automotive brand called “weather pack” or “weatherpak”) to keep oxygen and moisture away from the metal terminals. Although you can retrofit these style connectors to older harnesses, it takes a LOT of time, money, and effort to do so.
Now, contrast the insulating properties of di-electric grease to the electrically conductive properties of Conductive Grease, which, as its name implies, the grease itself (which contains many fine carbon particles) conducts electricity. Of course, being a “grease”, it too will also protect and insulate a terminal coated with it from moisture, corrosion, etc…..same as di-electric grease. But…it’s conductive, and if the terminal it coats is electrically “hot”, so is the grease (i.e. touching the grease alone will shock you!).
So a conductive grease is great when you need protection plus current flow……ideal for frame (or battery) grounds to the frame, etc. You could---if you are totally anally-retentive---coat (for instance) a battery post internally with conductive grease, and then cover all of that with di-electric grease.
So, think of these grease as two different electrical system “tools”, and use accordingly.
et2) Aftermarket electrical connector DI-ELECTRIC GREASE coats, insulates, and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Smear some of this goo on each and every one of your electrical connectors (after you've cleaned them with some sandpaper or terminal cleaner) and you'll be doing yourself a big favor!
HCP14059 Aftermarket packet of DI-ELECTRIC GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc.
$ 1.95
HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 14.95
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine grade grease, with adjustable nozzle size to tailor the grease output bead size to minimize slop and waste and making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 17.95
et14) Aftermarket electrical connector CONDUCTIVE GREASE coats and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Unlike the di-electric grease listed above, which is an insulator (non-conductive), this carbon-based grease is electrically conductive and has multiple applications (such as battery terminal posts (internally), frame grounds, etc.).
HCP27923 Aftermarket packet of CONDUCTIVE GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc. Even tiny amounts (that you can barely see) will create minimal electrical resistance, so be careful with this stuff around capacitors and such. It gets everywhere, will stain your hands and clothing and take three days to wash off, and smells like some of the worst goop you've ever smelled. Use a toothpick for application. Don't eat it. Wear gloves. 2-gram pouch goes a long way.
$ 3.95
cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.
HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 3.95
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine-grade grease, featuring an adjustable nozzle which allows you to tailor the grease output bead size to minimize slop and waste, while also making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 17.95
HCP10493 Aftermarket battery post TERMINAL SEALER helps keep corrosion from forming on the battery terminals. Fast drying and leaves no residue. Comes in a 6-ounce aerosol can.
$ 5.95
HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$ 8.95
HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 9.95
HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 4.95
HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 10.95
HCP10540 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery box with a sharp knife or a pair of scissors. For all XJ550, XJ650, XJ700, XJ750, and XJ900RK models.
$ 4.95
HCP10541 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery tray with a sharp knife or a pair of scissors. For all XJ1100 models.
$ 5.95
HCP10580 Aftermarket acid-neutralizing BATTERY TERMINAL PROTECTORS, thin, round felt mat circles are pressure-treated with a battery-acid neutralizing chemical. Placed under the battery terminal posts, they help prevents any spills or discharge from the battery from creating terminal corrosion. Trim and size to fit your battery posts with a sharp knife or a pair of scissors. Order 1 per terminal, 2 per battery. Each:
$ 1.00
Battery Box:
HCP1436 OEM original black plastic BATTERY BOX, bare, does contain any hardware or accessory pieces. Fits all 1981-83 XJ750 models.
$57.95
eb1) OEM battery RETAINING STRAP AND PADS---the short, flat, black "bungee cord" tension strap that holds the battery firmly in place within the battery box. Some models also use a white, hard plastic strap extension "hook" that attaches the upper end of the strap to the battery box.
HCP1442 OEM battery box CUSHION PAD, round black rubber pad fits into the back of the battery box and cushions the battery from movement. For all XJ550 and FJ600 models. Use 2 per bike. Each:
$ 4.95
HCP5789 OEM battery box CUSHION PAD, rectangular flat rubber pad fits into the bottom of the battery box and cushions the battery from movement. For all XJ700 and XJ750-X models. Use 1 per bike. NOTE: this pad is slightly smaller and thinner than the original. The aftermarket HCP16546 pad below is the current original size. Each:
$ 2.50
HCP16546 Aftermarket battery box CUSHION PAD, rectangular flat rubber pad fits into the bottom of the battery box and cushions the battery from movement. For all XJ700 and XJ750-X models. Use 1 per bike. NOTE: this pad is the correct original size and thickness. Each:
$ 4.95
Battery Retaining Straps:
HCP1448 OEM battery box BATTERY RETAINING STRAP, short flat black rubber strap with d-hooks on each end. For all XJ650 models (except Turbo), all 1981-83 XJ750 models, and XJ900RK, RL, N/FN, and F models. Each:
$ 19.95
HCP1444 OEM battery box BATTERY RETAINING STRAP, short flat black rubber strap with d-hooks on each end. For all XJ650 Turbo models. Each:
$ 9.50
HCP1445 OEM battery box BATTERY RETAINING STRAP, short flat black rubber strap runs front to back over the top of the battery. For all XJ700 and XJ750-X models. Each:
$ 10.95
HCP1446 OEM battery box BATTERY RETAINING STRAP, short flat black rubber strap runs from the bottom of the battery box up and over the top of the battery. For all XJ700 and XJ750-X models. Each:
$ 29.95
HCP23530 Aftermarket battery box BATTERY RETAINING STRAP, short flat black rubber strap runs from the bottom of the battery box up and over the top of the battery. For all XJ700 and XJ750-X models. Each:
$ 16.95
HCP1540 OEM battery box BATTERY RETAINING STRAP, short flat black rubber strap. For all XJ1100 models. Each:
$ 7.95
HCP8602 OEM battery box retaining strap EXTENSION HOOK, short flat white plastic strap runs from the top end of the battery retaining strap to the battery box. Used on all XJ650 models (except Turbo), all 1981-83 XJ750 models, and XJ900RK, RL, N/FN, and F models. Each:
$ 19.95
Battery Box Cover-to-Box Hardware:
HCP1030 OEM battery box cover-to-box SCREW, dark finish alloy steel, panhead, phillips drive. Use 2 per cover, for use on all XJ550 models, each:
$ 1.95
HCP2922 Aftermarket battery box cover-to-box SCREW, use 2 per cover, for use on all XJ550 models. Zinc-plated alloy steel, natural finish, panhead phillips-drive, each:
$ 1.50
HCP21362 Aftermarket battery box cover-to-box SCREW, use 2 per cover, for use on all XJ550 models. 18/8 stainless steel, bright finish, panhead phillips-drive, each:
$ 1.50
HCP6714 Aftermarket battery box cover-to-box SCREW, use 2 per cover, for use on all XJ550 models. Button head hex-drive, 18-8 stainless steel, bright finish, each:
$ 1.50
HCP6715 Aftermarket battery box cover-to-box SCREW, use 2 per cover, for use on all XJ550 models. Socket head, hex-drive, black-oxide coated alloy steel, each:
$ 1.75
HCP6716 Aftermarket battery box cover-to-box SCREW, use 2 per cover, for use on all XJ550 models. Socket head, hex-drive, 18-8 stainless steel, bright finish, each:
$ 1.95
HCP315 OEM battery box cover-to-box screw LOCK WASHER, use 2 per cover, for use on all XJ550 models, each:
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, battery box cover-to-box screw LOCK WASHER, use 2 per cover, for use on all XJ550 models, each:
$ 1.25
HCP319 Aftermarket 18-8 stainless steel battery box cover-to-box screw LOCK WASHER, use 2 per cover, for use on all XJ550 models, each:
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel battery box cover-to-box screw LOCK WASHER, use 2 per cover, for use on all XJ550 models, each:
$ 1.75
HCP4248 OEM battery box cover-to-box screw FLAT WASHER, bright zinc-plated alloy steel, use 2 per per cover, for use on all XJ550 models, each:
$ 2.95
HCP25871 Aftermarket battery box cover-to-box screw FLAT WASHER, bright zinc-plated alloy steel, use 2 per cover, for use on all XJ550 models, each:
$ 1.50
Battery Box-to-Frame Upper Mounting Hardware:
HCP4242 OEM battery box upper mounting BOLT, use 3 per box on all XJ550 and FJ600 models, each:
$ 3.50
HCP3029 OEM battery box upper mounting BOLT, standard 6-point hex-head alloy steel bolt with a dark finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models. Each:
$ 3.95
HCP14007 Aftermarket battery box upper mounting BOLT, standard 6-point hex-head alloy steel bolt with a yellow zinc-plated finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, black-oxide coated alloy steel. Each:
$ 1.75
HCP22249 Aftermarket battery box upper mounting BOLT, standard 6-point hex-head 18/8 stainless steel bolt with a bright finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 1.95
HCP14008 Aftermarket battery box upper mounting BOLT, standard 6-point hex-head 316 stainless steel bolt with a bright finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 1.25
HCP22253 Aftermarket battery box upper mounting BOLT, socket head (allen-key drive) alloy steel with a zinc-plated finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 1.95
HCP228 Aftermarket battery box upper mounting BOLT, socket head (allen-key drive) alloy steel with a black-oxide finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 1.00
HCP2779 Aftermarket battery box upper mounting BOLT, socket head (allen-key drive) alloy steel with a black-oxide finish, features self-locking threads. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 2.50
HCP226 Aftermarket battery box upper mounting BOLT, socket head (allen-key drive) 18/8 stainless steel with a bright finish. Use 1 per box on all XJ650 models, all 1981-83 XJ750, and all XJ900RK, RL, and N/FN models; and use 2 per box on all XJ700 and XJ750-X models, bright polished 18-8 stainless steel. Each:
$ 2.00
HCP13753 OEM battery box upper mounting BOLT, use 1 per box on all XJ900 F models. Each:
$ 1.50
HCP315 OEM battery box upper mounting bolt LOCK WASHER, use 3 per bike on all XJ550 and FJ600 models, use 1 per box on all XJ650, XJ750, XJ900RK, RL, and N/FN models, and use 2 per box on all XJ700 and XJ750-X models. Each:
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, battery box upper mounting bolt LOCK WASHER, use 3 per bike on all XJ550 and FJ600 models, use 1 per box on all XJ650, XJ750, XJ900RK, RL, and N/FN models, and use 2 per box on all XJ700 and XJ750-X models. Each:
$ 1.25
HCP319 Aftermarket 18-8 stainless steel battery box upper mounting bolt LOCK WASHER, use 3 per bike on all XJ550 and FJ600 models, use 1 per box on all XJ650, XJ750, XJ900RK, RL, and N/FN models, and use 2 per box on all XJ700 and XJ750-X models. Each:
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel battery box upper mounting bolt LOCK WASHER, use 3 per bike on all XJ550 and FJ600 models, use 1 per box on all XJ650, XJ750, XJ900RK, RL, and N/FN models, and use 2 per box on all XJ700 and XJ750-X models. Each:
$ 1.75
HCP4614 OEM battery box cover-to-box screw FLAT WASHER, use 3 per bike on all XJ550 and FJ600 models. Each:
$ 1.50
HCP10615 OEM battery box cover-to-box screw FLAT WASHER, use 1 per bike on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, and N/FN models, each:
$ 1.00
HCP3156 OEM battery box upper mounting bolt COLLAR, use 3 per box on all XJ550 and FJ600 models, and 1 per box on all XJ650 models, all 1981-83 XJ750 models, and all XJ900RK, RL, N/FN, and F models, each:
$ 7.95
HCP5792 OEM battery box upper mounting bolt COLLAR, use 2 per box on all XJ700 and XJ750-X models, each:
$ 4.95
HCP1947 OEM battery box upper mounting bolt GROMMET, use 3 per box on all XJ550 and FJ600 models, and 1 per box on all XJ650 models, all 1981-83 XJ750 models, and all XJ900RK, RL, N/FN, and F models, each:
$ 4.95
HCP5791 OEM battery box upper mounting bolt GROMMET, use 2 per box on all XJ700 and XJ750-X models, each:
$ 3.95
HCP26224 Aftermarket battery box upper mounting bolt GROMMET, use 2 per box on all XJ700 and XJ750-X models, each:
$ 2.95
Battery Box-to-Frame Lower Mounting Hardware:
HCP3925 OEM battery box lower mounting BOLT, alloy steel hex-head bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 2.95
HCP17143 Aftermarket battery box lower mounting BOLT, alloy steel hex-head bolt with a bright silver-zinc finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.25
HCP22195 Aftermarket battery box lower mounting BOLT, alloy steel hex-head bolt with a bright yellow-zinc finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.50
HCP17144 Aftermarket battery box lower mounting BOLT, alloy steel hex-head bolt with a black finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.95
HCP17145 Aftermarket battery box lower mounting BOLT, 18/8 stainless steel hex-head bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.75
HCP22198 Aftermarket battery box lower mounting BOLT, 316 stainless steel hex-head bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.95
HCP22200 Aftermarket battery box lower mounting BOLT, high-strength alloy steel socket head (hex-key) bolt with a black finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 3.95
HCP22201 Aftermarket battery box lower mounting BOLT, alloy steel socket head (hex-key) bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 3.95
HCP22202 Aftermarket battery box lower mounting BOLT, 18/8 stainless steel socket head (hex-key) bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 3.95
HCP24125 Aftermarket battery box lower mounting BOLT, 316 stainless steel socket head (hex-key) bolt with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 4.95
HCP3029 OEM battery tray lower mounting BOLT, standard 6-point hex-head alloy steel bolt with a dark finish. Use 2 per tray on all XJ1100 models, each:
$ 3.95
HCP14007 Aftermarket battery tray lower mounting BOLT, standard 6-point hex-head alloy steel bolt with a yellow zinc-plated finish. Use 2 per tray on all XJ1100 models, each:
$ 1.75
HCP22249 Aftermarket battery tray lower mounting BOLT, standard 6-point hex-head 18/8 stainless steel bolt with a bright finish. Use 2 per tray on all XJ1100 models, each:
$ 1.95
HCP14008 Aftermarket battery tray lower mounting BOLT, standard 6-point hex-head 316 stainless steel bolt with a bright finish. Use 2 per tray on all XJ1100 models, each:
$ 1.25
HCP22253 Aftermarket battery tray lower mounting BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Use 2 per tray on all XJ1100 models, each:
$ 1.95
HCP228 Aftermarket battery tray lower mounting BOLT, socket head (allen-key drive) alloy steel with a black-oxide finish. Use 2 per tray on all XJ1100 models, each:
$ 1.00
HCP2779 Aftermarket battery tray lower mounting BOLT, socket head (allen-key drive) alloy steel with a black-oxide finish, features self-locking threads. Use 2 per tray on all XJ1100 models, each:
$ 2.50
HCP226 Aftermarket battery tray lower mounting BOLT, socket head (allen-key drive) 18/8 stainless steel with a bright finish. Use 2 per tray on all XJ1100 models, each:
$ 2.00
HCP2185 OEM battery tray lower mounting bolt LOCK WASHER, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.95
HCP16209 Aftermarket battery tray lower mounting bolt LOCK WASHER, zinc-plated alloy steel, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 0.95
HCP16100 Aftermarket battery tray lower mounting bolt LOCK WASHER, 18-8 stainless-steel with a bright finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 0.95
HCP16102 Aftermarket battery tray lower mounting bolt LOCK WASHER, black-oxide coated finish, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 0.95
HCP315 OEM battery tray lower mounting bolt LOCK WASHER, use 2 per tray on all XJ1100 models, each:
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, battery tray lower mounting bolt LOCK WASHER, use 2 per tray on all XJ1100 models, each:
$ 1.25
HCP319 Aftermarket 18-8 stainless steel battery tray lower mounting bolt LOCK WASHER, use 2 per tray on all XJ1100 models, each:
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel battery tray lower mounting bolt LOCK WASHER, use 2 per tray on all XJ1100 models, each:
$ 1.75
HCP10062 OEM battery box lower mounting bolt COLLAR, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 4.95
HCP6271 OEM battery tray lower mounting bolt COLLAR, use 2 per tray on all XJ1100 models, each:
$ 5.95
HCP10063 OEM battery box lower mounting bolt GROMMET, use 1 per box on all XJ650, 1981-83 XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 5.25
HCP10061 OEM battery box lower oval back GROMMET, use 1 per box on all XJ650 and 1981-83 XJ750 models. The rear mounting "tab" of the chain lock storage box fits into this grommet. Each:
$ 1.95
HCP5790 OEM battery box lower mounting bolt GROMMET, use 1 per box on all XJ700 and XJ750-X models, each:
$ 5.25
BATTERY CABLES AND RELATED:
Battery Cables:
eb3) OEM and aftermarket replacement BATTERY CABLES correctly replace worn, frayed, damaged, or missing original positive or negative battery cables.
Original cables, terminal bars, and main harness lead wires come in the original lengths and configurations, either as stand-alone units or are integrated cable-and-lead wire units depending on model.
Aftermarket replacement cables are made from a heavy-duty 6-gauge wire, covered in either a red or black thermal- and fuel-resistant sheath, with crimped and soldered 1/4" closed-ring end terminals (note that the either or both end terminal are round ring terminals, rather than the original square peg terminal used on some models, but these will still fit onto the original battery posts or ground points just fine.....the ring terminals are easily bent to a 45-degree or 90-degree angle to accommodate the needed configurations for each bike). These cables are much-needed upgrade over corroded, damaged, or missing original cables.
Models that originally used an integrated cables can use these aftermarket cables as the battery cable only and make the suggested modifications listed below to retain or replace the "integrated" additional leads found on some original cables.
Positive (red) Battery Cables:
All OEM cable come complete with the battery post rubber cover and the solenoid-end protective rubber boot cap. Aftermarket cables do not feature the rubber caps or boots at either end.
NOTE: on XJ550 models, the original positive (+) battery lead from the battery to the starter relay ("solenoid") is a black-sheathed, braided wire cable. Why the factory choose to use a black cable for a positive battery lead is beyond me, but there it is.....
If you want to keep that as a black cable, you can use the HCP1605 black negative cable in it's place.....but we suggest that if you do replace this cable, you use the red-sheathed positive cable as is traditional for hot leads.
NOTE: on all XJ550, XJ650 Turbo, XJ700, XJ750, XJ900RK, and XJ1100 models, the main harness lead wire and connector is built into the positive battery cable. These replacement battery cables are just the heavy-gauge cable, and do not include the main harness lead. There are two solutions available to you:
1) if your original main harness lead wire is still in good condition, you can cut it off from your original battery cable, strip the cut end, and install one of the closed ring terminals listed below onto this end, which then allows you to install this connector onto the solenoid stud (XJ650 models used this method originally, using a separate battery cable which did not have the main harness lead wire integrated into the battery cable itself).
2) if you main harness lead wire is damaged, missing, or not re-usable, then you can purchase the separate HCP395 solenoid-to-main harness lead wire, complete with the ring terminal and the large white plastic connector block already installed.....ready to plug and play!
HCP2580 OEM POSITIVE BATTERY TERMINAL BAR. Fits all XJ650 models (except Turbo). Unlike a traditional battery cable, these models used a solid metal "bus bar" to connect the battery positive post to the solenoid, and then used the HCP395 solenoid-to-main harness lead wire.
$ 33.95
HCP23574 Aftermarket POSITIVE BATTERY TERMINAL BAR. Fits all XJ650 models (except Turbo). Unlike a traditional battery cable, these models used a solid metal "bus bar" to connect the battery positive post to the solenoid, and then used the HCP395 solenoid-to-main harness lead wire. Correct tin-plated reproduction of original.
$ 22.95
HCP21324 Aftermarket positive battery terminal bar RUBBER COVER. This odd “L” shaped rubber sanps onto and covers the HCP2580 or HCP23594 terminal bar and prevents all sorts of very bad things (i.e. big electrical shorts) from happening. Use on all XJ650 (except Turbo) models.
$ 21.95
HCP395 OEM solenoid-to-main harness POSITIVE WIRE LEAD, for all XJ650 (except Turbo) models, from the solenoid to the main harness. Includes the ring terminal for the solenoid end and plastic harness connector at the harness end already installed.
$ 32.95
HCP2938 OEM POSITIVE BATTERY CABLE, fits all XJ650 Turbo models, with integrated harness lead wire and connector. NOTE: this cable differs in overall length (it's longer), end terminal configuration, and post cover type. It will fit and work properly.
$ 39.95
HCP398 OEM POSITIVE BATTERY CABLE, fits all XJ700 and XJ750-X models, with integrated harness lead wire and connector.
$ 59.95
HCP396 OEM POSITIVE BATTERY CABLE, fits all XJ750 Seca and XJ900RK, RL, N/FN, and F models. Has the integrated main harness lead wire and connector. NOTE: this cable can be used as a suitable replacement for the original XJ550 positive cable, but this cable has a red cable rather than the original black cable used on the XJ550 models.
$ 49.95
HCP1600 Aftermarket red 6-gauge POSITIVE BATTERY CABLE, 4" long, can be used as a substitute for the original metal positive battery "bar" used on all XJ650 (except Turbo) models.........however, it will be a tight fit. Each:
$ 11.95
HCP1601 Aftermarket red 6-gauge POSITIVE BATTERY CABLE, 6" long. This cable can be used to replace the original black-sheathed positive battery cable on all XJ550 models, and the original metal terminal bar on all XJ650 models (except Turbo). XJ550 owners will either have to save and modify/re-use their main harness connector lead wire off of your original cable, or use the HCP395 solenoid-to-main harness lead wire, while the XJ650 crowd (except Turbo) can re-use their original separate solenoid-to-main harness lead wire. Each:
$ 12.95
HCP11428 Aftermarket black 6-gauge POSITIVE BATTERY CABLE, 6" long. This cable can be used to replace the original black-sheathed positive battery cable on all XJ550 and XJ1100 models. You will need to save and re-use the main harness plastic connector lead wire off of your original cable....or use our HCP12837MFWHT replacement connector below... as this cable comes with a red harness lead wire, but it is terminated with a sheathed female bullet connector instead of the proper large plastic connector shell. XJ1100 owners can modify your existing wire harness by removing the white connector shell and substituting a male bullet terminal on that wire, then it will integrate with the HCP11428 harness properly.
Each:
$ 21.95
HCP9364BR1418 Aftermarket MALE BULLET STYLE WIRE-END TERMINAL, correct size and style solid brass terminal features retention bulge for insertion and positive locking into the female mate. Accepts 14-18 gauge wires. Each:
$ 1.95
HCP1605 Aftermarket black 6-gauge BATTERY CABLE, 6" long. This cable can be used to replace the original black-sheathed, integrated positive battery cable on all XJ550 models. You will either have to save and modify/re-use the main harness connector lead wire off of your original cable, or use the HCP395 solenoid-to-main harness lead wire. Each:
$ 12.95
HCP1602 Aftermarket red 6-gauge POSITIVE BATTERY CABLE, 8" long. This cable can be used to replace the original integrated positive battery cable on all XJ650 Turbo, XJ750 non-X, and XJ900RK models. You will either have to save and modify/re-use the main harness connector lead wire off of your original cable, or use the HCP395 solenoid-to-main harness lead wire. Each:
$ 13.95
HCP1603 Aftermarket red 6-gauge POSITIVE BATTERY CABLE, 10" long. This cable can be used to replace the original integrated positive battery cable on all XJ700-X and XJ750-X models. You will either have to save and modify/re-use the main harness connector lead wire off of your original cable, or use the HCP395 solenoid-to-main harness lead wire. Each:
$ 13.95
HCP395 OEM POSITIVE WIRE LEAD, from the solenoid to the main wire harness connector.
$ 32.95
Battery Cable Terminal Covers and Boots:
Since the positive battery cable is always "hot", all exposed ends of these cables are protected by rubber COVERS or BOOTS. Over time, these flexible rubber protective pieces get ripped, torn, or lost, leaving a live positive terminal just waiting to cause a short, a spark, or a fire!
HCP11318 OEM positive battery cable COVER, at the battery post. For all XJ700 and XJ750-X models.
$ 29.95
HCP11321 OEM positive battery cable COVER, at the battery post. For all XJ900RK, RL, N/FN, and F models.
$ discontinued
HCP11431 Aftermarket positive battery cable (at solenoid) RUBBER TERMINAL BOOT, use 1 per cable. Fits over the end terminal and covers the solenoid terminal stud. Slightly smaller than original and will require some "persuasion" (and lubrication) to fit over the battery cable end terminal properly. Fits all XJ550, FJ600, XJ650 Turbo, XJ700, XJ750, XJ900RK, and XJ1100 models. Can be used on XJ650 Maxim, Midnight Maxim, and RJ Seca models, but this is just the small end cover for the stud and is not a "full-length" cover as originally used on these models. Each:
$ 11.95
Negative (black) Battery and Frame Ground Cables:
NOTE: on all XJ550, XJ700, and XJ750-X models, the negative battery cable is "integrated" with a separate, small gauge harness ground lead wire. These replacement battery cables are just the heavy-gauge cable, and do not include the smaller accessory lead wire. These models will require you to salvage the accessory wire cut it off from your original battery cable, strip the cut end, and install one of the closed ring terminals listed below onto this end, which then allows you to install that original wire onto it's main harness mating terminal or connector.
HCP2937 OEM black NEGATIVE BATTERY CABLE, fits all XJ1100 models.
$ 25.95
HCP1604 Aftermarket black 6-gauge NEGATIVE BATTERY CABLE, 4" long. Each:
$ 12.95
HCP1605 Aftermarket black 6-gauge NEGATIVE BATTERY CABLE, 6" long. This cable can be used as a replacement negative battery cable on all XJ1100 models. Each:
$ 13.95
HCP11429 Aftermarket black 6-gauge NEGATIVE BATTERY CABLE, 7" long. This cable can be used as a replacement negative battery cable on all XJ1100 models. Each:
$ 12.95
HCP1606 Aftermarket black 6-gauge NEGATIVE BATTERY CABLE, 8" long. This cable can be used to replace the original TCI-to-frame ground cable on all XJ650 (except Turbo), XJ750 Maxim and XJ750 Midnight Maxim models. Each:
$ 13.95
HCP1607 Aftermarket black 6-gauge NEGATIVE BATTERY CABLE, 10" long. This cable can be used as a direct replacement for the original negative battery cable on all XJ650 models (except Turbo), and also to replace the original integrated negative battery cable on all XJ550, XJ700, and XJ750-X models. You will have to save, modify, and re-use the additional ground wire off of your original cable. NOTE: this cable will be a tight fit on some of these models, but it will reach! Each:
$ 14.95
Battery Cable Terminals and Hardware:
As mentioned previously, when replacing an "integrated" style original battery cable to an aftermarket cable, if your original positive cable has the main harness lead wire integrated into the battery cable, you will either have to salvage the main harness lead off of your original cable, and then add a proper sized RING TERMINAL to the end of it (and attach this ring terminal to the solenoid "hot" stud, same as what the positive battery cable is attached to), or, you will need to replace your original main harness lead wire with our HCP395 solenoid-to-main harness POSITIVE WIRE LEAD unit, which is ready to plug-and-play and has both wire ends properly terminated.
Some negative battery cables also were of the "integrated" type, with an additional small-gauge ground wire lead that plugged into a matching main harness connector. For such models, when using our replacement ground cables, you should cut off the small secondary wire and terminate it with a ring connector, and then install it along with the battery ground cable at it's original location.
HCP395 OEM solenoid-to-main harness POSITIVE WIRE LEAD, for use on all on the following models either as an original replacement, or as a plug-and-play replacement when using an aftermarket positive battery cable to replace an original "integrated" positive cable. Can be used as a replacement on all XJ550 models, XJ650 Turbo, XJ700, XJ750, and XJ900RK models. Includes the ring terminal for the solenoid end and plastic harness connector at the main harness end already installed.
$ 32.95
HCP12837MFWHT Aftermarket white plastic MALE CONNECTOR SHELL, single place, used on all of the following circuits listed below. Accepts the HCP12898BR1418 female flat-blade terminal. Each:
$ 5.95
* HCP12837MFWHT (the male shell with the female latching peg) is used on:
- Main battery power lead-in harness, on the positive battery cable harness side of the connection: all XJ models except XJ1100 models.
HCP12898BR1418 Aftermarket original style "large" straight brass FEMALE LARGE FLAT BLADE TERMINAL. Used only within the main battery lead male connector shell HCP12837MFxx on all models except XJ1100. Each:
$ 1.25
HCP10092TP1218 Aftermarket brass closed RING TERMINAL, original crimp-on style connector (we recommend soldering as well as crimping for electrical integrity of the connection). Proper size for the hot solenoid stud, or for use with any of the engine case ground bolts. Terminal only, no insulation included. Each:
$ 0.95
HCP11134BRK Aftermarket brass closed RING TERMINAL, original crimp-on style connector (we recommend soldering as well as crimping for electrical integrity of the connection). Proper size for the hot solenoid stud, or for use with any of the engine case ground bolts. Terminal with clear insulating sleeve included. Each:
$ 1.95
HCP11317 OEM battery post EXTENSION TERMINAL. Used only on XJ750 air-cooled models and on the XJ900RK models, this L-shaped bent metal extension bar converts the negative battery post into a "side post" to accept the ring terminal on the end of the battery cable. Uses the standard battery post phillips-drive hex screw to secure the cable to this terminal. XJ750 Seca models and XJ900RK, RL, N/FN, and F models use this extender terminal on both the negative and positive battery posts, while the 1982-83 XJ750 Maxim and Midnight Maxim models use this extender only on the positive post. Each:
$ 34.95
HCP11322 OEM battery post SCREW. Used on all XJ models, this is the special hex-head bolt with a phillips-drive screw slot. Used to secure the positive or negative battery cable to the battery posts when used with the original rectangular post nut. Each:
$ 2.95
HCP11444 OEM battery post screw special thin WASHER, used under the head of the HCP11322 screw on both the positive or negative battery cables. Made of standard carbon steel. Each:
$ 0.75
HCP11445 OEM battery post screw special thin WASHER, used under the head of the HCP11322 screw on both the positive or negative battery cables. Made of 18/8 stainless steel. Each:
$ 1.25
HCP11443 OEM battery post screw special rectangular POST NUT, tall and narrow, it's designed to fit inside the post (regular nuts are too wide to fit). Use on both the positive or negative battery cables. Made of standard carbon steel. Each:
$ 1.95
STARTER RELAY - SOLENOID AND RELATED:
ep6) OEM and Aftermarket STARTER RELAY and SOLENOID. This round canister style solenoid has two terminal studs, the wire harness pigtail and connector, and is mounted into a rubber insulator.
Your positive battery cable connects to one terminal on the solenoid, and the other terminal feeds the cable to the starter motor. The wire harness pigtail goes to your "start" push-button.
HINTS: be aware that the blue/white wire coming off of the starter solenoid is what leads to the push-switch on your handlebar control unit, and provides the GROUND circuit for the solenoid........in other words, when you push the "start" button on the handlebar switch, all that does is complete the solenoid circuit (it provides the ground path). Thus, if the switch internals (on the start button switch) or the handlebar control switch ground is not secure, clean, etc. that may be the real problem with the solenoid.
You can verify whether this is the problem by jumping the blue/white wire off of the solenoid directly to battery terminal negative........if the solenoid works properly, then the problem is not (fully) with the solenoid, but with something else in the ground path for the solenoid.
If your starter motor doesn't work, and all you hear is a "click" when you press the starter button, either your battery is dead or this relay - solenoid unit is the culprit. If your starter button doesn't operate the starter ("click"), but you can short across the two big terminal studs on the front of this solenoid and engage the starter motor, then the relay within the solenoid is probably bad and this solenoid needs to be replaced.
Here's a good overview of the diagnosis process for problems with a "no-start" condition:
http://www.xjbikes.com/forums/threads/won’t-start-1983-yamaha-xj750-maxim.118050/#post-591103
and
https://www.xjbikes.com/forums/threads/help-me-plz.125369
HCP449 OEM starter Relay - SOLENOID, fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. NOTE: this relay is slightly smaller in the diameter of the can (about 1/4" smaller), and it is also about 2" shorter, end-to-end; however, it will fit into the original rubber insulator/holder and will perform as original. Correct colored lead wires off the solenoid have the correct white plastic 2-space wiring harness connector. Includes the rubber mounting grommet: Each:
$ 64.95
HCP1680R Aftermarket starter Relay - SOLENOID, fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. NOTE: this relay is slightly smaller in the diameter of the can (about 1/4" smaller), and it is also about 2" shorter, end-to-end; however, it will fit into the original rubber insulator/holder and will perform as original. Correct colored lead wires off the solenoid have the correct white plastic 2-space wiring harness connector. Includes the rubber mounting grommet: Each:
$ 54.95
HCP22645 OEM starter Relay - SOLENOID, fits all 1992-98 XJ600 Seca II models, each:
$ 122.95
HCP2572 OEM starter Relay - SOLENOID, fits all XJ700 and XJ750-X models. Includes the rubber mounting grommet: Each:
$ 77.95
HCP1681K Aftermarket starter Relay - SOLENOID, fits all XJ700 and XJ750-X models. Correct colored lead wire off the solenoid has the correct "bullet" wiring harness connector. Includes the rubber mounting grommet: Each:
$ 64.95
HCP1682 Aftermarket starter Relay - SOLENOID, fits all XS1100 models. Correct colored lead wires off the solenoid have the correct white plastic 2-space wiring harness connector. Includes the rubber mounting grommet: Each :
$ 57.95
NOTE: the following terminal stud nut and lock washers come with all of the above complete solenoids. They are offered separate here for those people repairing or replacing missing components on original solenoids:
HCP3996 OEM starter solenoid terminal stud NUT, alloy steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95
HCP16570 Aftermarket starter solenoid terminal stud NUT, 18/8 stainless steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95
HCP3703 OEM starter solenoid terminal stud NUT, use 2 per unit. Bright zinc-plated steel. Fits all 1992-94 XJ600 Seca II, and XJ900 F models. Each:
$ 2.95
HCP10962 Aftermarket starter solenoid terminal stud NUT, use 2 per unit. Yellow zinc-plated steel. Fits all 1992-94 XJ600 Seca II, and XJ900 F models. Each:
$ 1.95
HCP3704 OEM starter solenoid terminal stud NUT, use 2 per unit. Black plated alloy steel. Fits all 1995-98 XJ600 Seca II models. Each:
$ 2.95
HCP10001 Aftermarket starter solenoid terminal stud NUT, use 2 per unit. Black plated alloy steel. Fits all 1995-98 XJ600 Seca II models. Each:
$ 1.95
HCP315 OEM starter solenoid terminal stud LOCK WASHER, use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, starter solenoid terminal stud LOCK WASHER, use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Eachch:
$ 1.25
HCP319 Aftermarket 18-8 stainless steel starter solenoid terminal stud LOCK WASHER, use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel starter solenoid terminal stud LOCK WASHER, use 2 per unit. Fits all XJ550, 1984-85 FJ600, 1986-88 YX600 Radian XJ650, 1981-84 XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.75
Solenoid-to-Starter Motor Cable:
HCP11430 Aftermarket solenoid-to-starter motor CABLE, fits all XJ550 and FJ600 models. Slightly shorter than original, but will reach if the cable installation by-passes the lower frame band-strap (by the battery ground cable location on the engine block). Correct soldered and crimped terminals. End boots are included. Each:
$ 14.95
HCP11426 OEM solenoid-to-starter motor CABLE, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, and N/FN models. Correct soldered and crimped terminals. End boots are not included and must be re-used or purchased separate. Each:
$ 14.95
HCP2951 OEM solenoid-to-starter motor cable RUBBER TERMINAL BOOT, use 2 per cable. Fits over the end terminals and covers the solenoid terminal stud and the starter brush stud, protecting from moisture and shorts. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, XJ900RK, and XJ1100 models. Each:
$ discontinued
HCP11431 Aftermarket solenoid-to-starter motor cable RUBBER TERMINAL BOOT, use 2 per cable. Fits over the end terminals and covers the solenoid terminal stud and the starter brush stud, protecting from moisture and shorts. Slightly smaller than original and will require some "persuasion" (and lubrication) to fit over the starter motor stud boss fitting properly. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, XJ900RK, and XJ1100 models. Each:
$ 17.95
STARTER MOTORS:
gp2) OEM new and aftermarket re-wound STARTER MOTORS perfectly replace the originals. Rewound starters are sold on a "core charge" basis and you must return to us a usable, same-model starter motor core in order to receive your core charge refund.
Checking Starter Motors:
As far as checking your starter motor, the only tests that you can do are on the commutator (the segmented "snout" of the entire armature) and the brushes, and are as follows:
a) if the surface is commutator is dirty, clean it with 800-grit or finer sandpaper or crocus cloth. Make sure that any dust generated by this process is completely removed.
b) the mica insulation on the armature.....in between each of the raised "segments"......should be:
* 0.8mm (.03") below the level of adjoining segments on XJ550, FJ600, FZ600, and YX600 starter motors.
* 0.6mm (.025") below the level of adjoining segments on all XJ650, XJ700, XJ750, and XJ900 starter motors.
If the depth of this mica insulation below the level of the segments is less than the specifications given above, you should scrape away the insulation until that depth is reached (a hacksaw blade or similar tool can be shaped to fit), or take the armature to an electrical service shop to have them undercut the mica to the appropriate depth.
c) check the raised segments for continuity between each individual segment and each and every other segments. There should be continuity.
d) check for continuity between every segment (assuming the test in "c" above has already been performed) and the shaft of the armature. There should not be any continuity. Note that shorted commutator rings can also cause a reverse-direction (“backwards”) motor spin….. the correct direction of rotation would be in the same direction as your tires rotate when moving forward (orientation as when the starter motor is installed on the bike; thus, when viewing the starter motor from the butt end-----not the gear end----that would be counter-clockwise.)
e) check the resistance of the internal coil windings of the armature. You do this via measuring the resistance across every two adjoining segments. It should be:
* 0.012 ohms +/- 6% at 70-degrees F. for all XJ550, FJ600, FZ600, and YX600 starter motors.
* 0.014 ohms +/- 6% at 70-degrees F. for all XJ650, XJ700, XJ750, and XJ900 starter motors.
f) measure the outside diameter of the segments. The minimum acceptable diameter is 27.00mm.
If any of the above tests (c-f) fails, then the armature is bad and needs to be replaced.
g) measure the length of the brushes. The minimum acceptable length is:
* 5.00mm for all XJ550, FJ600, FZ600, and YX600 starter motors.
* 8.50mm for all XJ650, XJ700, XJ750, and XJ900 starter motors.
h) check for continuity between each brush and the brush plate. There should be continuity.
i) check for continuity between each brush and its terminal bolt. There should be continuity.
j) check the condition of the shaft end bushings or bearings in the case. If they are worn, then they needs to be replaced.
k) check the condition of the ring and planetary gears. If they are worn or chipped, then they need to be replaced.
l) the only other procedure that is mentioned in the factory manual is to check the condition of the brush springs, and you are supposed to do that by comparing them to new ones.....which is kind of hard to do! The springs should be considered serviceable if they snap the brushes firmly back into position when released from tension. The exact specification is:
* 550 +/- 50 grams (18.5 +/- 1.5 ounces) of pressure, measured via the use of a spring gauge, for all XJ550, FJ600, FZ600, and YX600 starter motors.
* 800 +/- 150 grams (28.22 +/- 5.29 ounces) of pressure, measured via the use of a spring gauge, for all XJ650, XJ700, XJ750, and XJ900 starter motors.
Also, be very careful when re-assembling a starter motor. There is an alignment notch in the brush plate that must be aligned with the case properly, as well as alignment notches on the outside of the main case to the end caps. Failure to install the brushes and brush plate in their proper orientation can cause the starter motor to not work at all, or to even spin backwards! The correct rotation of the starter motor is counter-clockwise, looking at the butt-end of the motor (as it is installed on the engine); or, clockwise if you're looking the starter drive gear dead in its eye..........
Another simple check is to rotate the external toothed gear with your hand clockwise (as viewed from gear end of the starter motor). Place a voltmeter positive lead (the red probe) on the large terminal of the starter motor (the one that the battery cable is normally attached to), and place the voltmeter negative lead (the black probe) grounded somewhere on the engine case or frame. You should see about a positive 0.3 volts (DC) being generated when you rotate the gear.
Finally, always be sure to use a premium, high-temperature grease to lubricate the internal gears and bearings, and do not attempt to clean the armature via the use of strong solvent sprays (brake cleaner, carb cleaner, etc.) as the solvents may break down the insulation on the coil windings, causing an internal short.
Complete Starter Motors:
NOTE: Due to the weight of starter motors, the free or reduced shipping charges offer may not apply to these items!
HCP4155 Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and *1986-90 YX600 Radian models. This unit has the silver finish and is correct only for XJ550 models, but will fit all of the above models. *NOTE: these are the 4-brush Mitsuba style motors which were originally supplied on the 1986-88 YX600 engines; 1989-90 models used a 2-brush motor which is not available. The 4-brush motor will fit and work properly as a direct replacement for the original 2-brush motor. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 189.95 + $ 115.00 core charge
HCP20068 OEM original, brand new STARTER MOTOR fits all 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. This unit has a black finish and is correct only for the FJ600, FZ600, and YX600 models, but will also fit XJ550 models. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 499.95 + $ 115.00 core charge
HCP20435 Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and *1986-90 YX600 Radian models. This unit has a black finish and is correct only for the FJ600, FZ600, and YX600 models, but will also fit XJ550 models. *NOTE: these are the 4-brush Mitsuba style motors which were originally supplied on the 1986-88 YX600 engines; 1989-90 models used a 2-brush motor which is not available. The 4-brush motor will fit and work properly as a direct replacement for the original 2-brush motor. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 159.95 + $ 115.00 core charge
HCP19794 Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ600 Seca II models, this version features the silver end cap (at the cable end) which is correct for 1992-95 models (1996-98 models used the same motor, but with a black-painted end cap). A $ 95.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end cap and case, and all of the gears cannot be damaged or chewed up in any way.
$ 219.95 + $ 95.00 core charge
HCP19794BLK Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ600 Seca II models, this version features the black end cap (at the cable end) which is correct for 1996-98 models (1992-95 models used the same motor, but with a silver-painted end cap). A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE:
"re-usable" means it is complete and has not been physically damaged in any way, in particular the end cap and case, and all of the gears cannot be damaged or chewed up in any way.
$ 229.95 + $ 115.00 core charge
HCP476 OEM original, brand new STARTER MOTOR fits all XJ650, XJ700, XJ750, and XJ900 models. Features the correct silver finish on the case, which is correct for all of the following models: XJ650 Maxim, 1985 XJ700 N/NC air-cooled models, 1981-84 XJ750 Maxim, 1981-82 XJ750 Seca, and XJ900F, N, and FN models. A $ 95.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 479.95 + $ 95.00 core charge
HCP4156 Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ650, XJ700, XJ750, and XJ900 models. Features the correct silver finish on the case, which is correct for all of the following models: XJ650 Maxim, 1985 XJ700 N/NC air-cooled models, 1981-84 XJ750 Maxim, 1981-82 XJ750 Seca, and XJ900F, N, and FN models. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 189.95 + $ 115.00 core charge
HCP477 OEM original, brand new STARTER MOTOR fits all XJ650, XJ700, XJ750, and XJ900 models. Features the correct black finish on the case, which is correct for all of the following models: XJ650 Midnight Maxim, XJ650 Turbo, XJ650RJ Seca, XJ700 all (except 1985 N/NC air-cooled) models, XJ750 Midnight Maxim, 1983 XJ750 Seca, XJ750RL Seca, XJ750-X, and XJ900RK and RL models. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 499.95 + $ 115.00 core charge
HCP4156BLK Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ650, XJ700, XJ750, and XJ900 models. Features the correct black finish on the case, which is correct for all of the following models: XJ650 Midnight Maxim, XJ650 Turbo, XJ650RJ Seca, XJ700 all (except 1985 N/NC air-cooled) models, XJ750 Midnight Maxim, 1983 XJ750 Seca, XJ750RL Seca, XJ750-X, and XJ900RK and RL models. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ discontinued
HCP4157 Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ1100 and XS1100 models. Silver finish on the end cap, which is correct for all XJ1100 and XS1100 Standard and Special (except Midnight Special) models.. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 219.95.00 + $ 115.00 core charge
HCP4157BLK Aftermarket rebuilt/re-wound STARTER MOTOR fits all XJ1100 and XS1100 models. Black finish on the end cap, which is correct for all XS1100 Midnight Special models.. A $ 115.00 core charge applies to this item, and a re-usable, same-model starter motor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, in particular the end caps and case, and all of the gears cannot be damaged or chewed up in any way.
$ 229.95 + $ 115.00 core charge
Starter Motor Rebuild Parts:
sms3) An assortment or original OEM and aftermarket starter motor rebuild parts are available----BRUSHES, O-RINGS, GASKETS, ETC. See the complete list of items available below.
This information should assist you in visualizing what the starter motor rebuild process will involve. Although shown is the XJ650/700/750/900 type starter motor, the same process applies to all XJ models:
and
http://xjbikes.com/forums/index.php?threads/45727
and a great video of the entire process from start (no pun intended) to finish:
And though you may not have your own personal growler, follow these basic tips anyway while you have your starter motor apart for the rebuild:
https://www.xjbikes.com/forums/threads/tackling-starter-rebuild-this-weekend.123652
XJ550, 1984-85 FJ600, 1986-88 FZ600, and *1986-90 YX600 Radian models:
*NOTE: while most of the models listed here use the tried-and-true 4-brush (2 positive brushes and 2 negative brushes) Mitsuba starter motors, some 1989-90 YX600 models were fitted with 2-brush motors (a single positive and single negative brush), and as such any electrically-related rebuild parts and rebuild kits listed below are not correct and will not work in such 2-brush motors. While the 2-brush and 4-brush motors used on these models will physically interchange with each other as a complete unit, their internals are different and will not interchange. Owners with the 2-brush motors can use the HCP27307 brushes-and-plate set listed further below for the 1992-98 XJ600 Seca II models, but that is the only rebuild part we have available for the 2-brush motors (although that brush plate assembly for the Seca II starter will work on these earlier 2-brush Mitsuba starter motors, none of the other components will interchange, as they are completely different design motors).
It is also possible that if your original starter motor was replaced at some time in the dim-and-distant past, the replacement motor (whether new or rebuilt) may have been a 2-brush or a 4-brush version, so you should check carefully before ordering. Obviously, due to the much broader original usage of the 4-brush motors, they are much more common than the 2-brush motors.
HCP4020 Aftermarket starter motor BRUSHES SET, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-88 YX600 Radian models. Set of four brushes, two positive and two negative. Order one set to do one starter. NOTE: you must be able to fabricate a method of attaching the brush leads to your original brush plate. Original leads are attached using special equipment which is not possible to duplicate using common methods (soldering, etc.). A much better solution is to replace the entire brush plate assembly with one of part numbers below.
$ 22.95
HCP485 OEM starter motor BRUSHES AND PLATE SET, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-88 YX600 Radian models. Contains the negative brushes and their mounting plate, and the positive brushes and their holder "band". NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 129.95
HCP4160 Aftermarket starter motor BASIC REBUILD KIT, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-88 YX600 Radian models. This basic rebuild kit includes the negative brushes and their mounting plate, the positive brushes and their holder "band", the end cap rubber ring gaskets, a positive post stud, the stud insulator, and stud hardware. NOTE: brushes and plate differ in appearance and fitment from original but are designed to work properly in original starter motors. There is a molded plastic insulator “shroud” (not used in original starter motors) that must be used with the components in this kit.
$ 49.95
HCP18273 Aftermarket starter motor COMPLETE REBUILD KIT, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-88 YX600 Radian models. Complete rebuild kit contains the negative brushes and their mounting plate, the positive brushes and their holder "band", a nose o-ring, the end cap rubber ring gaskets, the shaft end bushing, that shaft center support bushing, the shaft bearing, shaft oil seal, reduction gear bushings, circlips, positive post stud, stud insulator, and stud hardware. All the items necessary to do a complete starter motor overhaul. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors. This is the only complete kit on the market, as all other “complete” rebuild kits out there do not include the positive stud, and your original stud will not fit the positive brushes holder included in aftermarket rebuild kits!
$ 69.95
HCP478 OEM starter motor snout-to-engine case O-RING, fits all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, and 1986-90 YX600 Radian models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ discontinued
HCP2321 Aftermarket starter motor snout-to-engine case O-RING, fits fits all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, and 1986-90 YX600 Radian models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 12.95
HCP4845 OEM starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. Use 1 per starter. . NOTE: this is the smaller of the two circlips, located on the very end of the shaft
$ 7.95
HCP22885 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Black phosphate coated spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 4.95
HCP23688 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Passivated 400-series stainless spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 5.95
HCP23677 Aftermarket starter motor SHAFT CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. Black phosphate coated spring steel. Use 1 per starter. NOTE: this is the larger of the two circlips, located midway down the shaft, below the drive gear and above the ball bearing.
$ 5.95
HCP2568 OEM starter motor positive brush lead stud INNER NUT, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models, not the same in appearance as original but will work properly. This flanged nut secures the positive brush stud to the motor case.
$ 6.95
HCP315 OEM starter motor positive brush lead stud LOCK WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models, not the same in appearance as original but will work properly.
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, starter motor positive brush lead stud LOCK WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models.
$ 1.25
HCP319 Aftermarket 18-8 stainless steel starter motor positive brush lead stud LOCK WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models.
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel starter motor positive brush lead stud LOCK WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models.
$ 1.75
HCP2176 OEM starter motor positive brush lead stud OUTER NUT, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and all XJ900 models, not the same in appearance as original but will work properly. This nut secures the starter motor power cable to the positive brush lead wire stud.
$ 2.95
HCP24035 Aftermarket starter motor positive brush lead stud OUTER NUT, made from 18/8 stainless steel, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and all XJ900 models. This nut secures the starter motor power cable to the positive brush lead wire stud.
$ 1.95
HCP2563 OEM starter motor MAIN CASE GASKET, seals the end caps to the center case. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-88 YX600 Radian models. Use 2 per starter on all 4-brush motors, and use 1 per starter (at the “engine end” cap) on 2-brush motors (primarily 1989-90 YX600 Radian models). Each:
$ 28.95
HCP27301 OEM starter motor MAIN CASE GASKET, seals the end caps to the center case. Use 2 per starter on all 1992-98 XJ600 Seca II, 1988-90 FZR400, 1989-99 FZR600R, and 1995-07 YZF600R engines. Use 1 per starter (at the “outer end” cap) on 2-brush motors (primarily 1989-90 YX600 Radian models). Each:
$ 39.95
NOTE: the following bolts secure and "cinch together" one end cap to the other end cap, holding them tight to the central starter motor main body:
HCP14288 Aftermarket starter motor CASE BOLT, cinches the end caps together to the center case. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. This allen-drive, socket head cap screw replaces the original phillips-drive, panhead screw, and is made from a bright-finish 18-8 stainless steel material. Use with the HCP319 lockwasher below. Use 2 per starter. Each:
$ 3.95
HCP14289 Aftermarket starter motor CASE BOLT, cinches the end caps together to the center case. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. This allen-drive, socket head cap screw replaces the original phillips-drive, panhead screw, and is made from a black-oxide coated alloy steel material. Use with the HCP321 lockwasher below. Use 2 per starter. Each:
$ 4.95
HCP319 Aftermarket starter motor case bolt LOCK WASHER, 18-8 stainless steel. Use with the HCP14288 case bolt above. Each.
$ 1.00
HCP321 Aftermarket starter motor case bolt LOCK WASHER, black-oxide coated alloy steel. Use with the HCP14289 case bolt above. Each.
$ 1.50
NOTE: the following are the two forward bolts (at the 7- and 11-o’clock positions) that secure the starter motor end cap to the engine:
HCP3197 OEM starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Black finish. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models. Use 2 per starter. Each:
$ 2.50
HCP21306 Aftermarket starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Black finish. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1996-98 XJ600 Seca II models. Use 2 per starter. Each:
$ 1.50
HCP27308 Aftermarket starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Bright finish. Fits all 1992-95 XJ600 Seca II models. Use 2 per starter. Each:
$ 1.95
NOTE: the following is used to secure the starter motor end cap at the rear (4-o’clock position) to the shifter case cover:
HCP966 OEM starter motor mounting MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Correct for all XJ550 models. Each:
$ 2.50
HCP971 OEM starter motor mounting MOUNTING BOLT, allen head hex-drive, black finish. Correct for all 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. Each:
$ 2.50
HCP22253 Aftermarket starter motor mounting MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian models. Each:
$ 1.95
HCP228 Aftermarket starter motor mounting MOUNTING BOLT, allen head hex-drive, black-oxide coated steel. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian models. Each:
$ 1.00
HCP2779 Aftermarket starter motor mounting MOUNTING BOLT, allen head hex-drive, black-oxide finish, features self-locking threads. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian models. Each:
$ 2.50
HCP226 Aftermarket starter motor mounting MOUNTING BOLT, allen head hex-drive, bright 18-8 stainless steel finish. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian models. Each:
$ 2.00
1992-98 XJ600 Seca II models:
HCP27307 OEM starter motor BRUSH AND PLATE SET, fits all 1992-98 XJ600 Seca II models. Complete set of brushes with the mounting plate, positive stud, and stud hardware. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 219.95
HCP27294 Aftermarket starter motor COMPLETE REBUILD KIT, fits all 1992-98 XJ600 Seca II models. Complete set of two brushes with the mounting plate, nose o-ring, end cap gaskets, needle bearing and oil seal, armature shaft bushing and shim washers, positive post stud insulator and associated hardware. All the items necessary to do a complete starter motor overhaul. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 59.95
HCP22538 OEM starter motor snout-to-engine case O-RING, fits all 1992-98 XJ600 Seca II and 1992-2002 XJ600 Euro models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 7.95
HCP1536 Aftermarket starter motor snout-to-engine case O-RING, fits all 1992-98 XJ600 Seca II and 1992-2002 XJ600 Euro models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 6.95
HCP27301 OEM starter motor MAIN CASE GASKET, seals the end caps to the center case. Use 2 per starter on all 1992-98 XJ600 Seca II, 1988-90 FZR400, 1989-99 FZR600R, and 1995-07 YZF600R engines. Use 1 per starter (at the “outer end” cap) on 2-brush motors (primarily 1989-90 YX600 Radian models). Each:
$ 39.95
HCP2568 OEM starter motor positive brush lead stud INNER NUT, fits all 1992-98 XJ600 Seca II models. This flanged nut secures the positive brush stud to the motor case. Use 2 per motor. Each
$ 6.95
NOTE: the following bolts secure and "cinch together" one end cap to the other end cap, holding them tight to the central starter motor main body:
HCP27302 OEM starter motor CASE BOLT, cinches the end caps together to the center case. Fits all 1992-98 XJ600 Seca II, 1988-90 FZR400, 1989-99 FZR600R, and 1995-07 YZF600R engines. Use 2 per starter. Each:
$ 23.95
NOTE: the following are the two forward bolts (at the 7- and 11-o’clock positions) that secure the starter motor end cap to the engine:
HCP3197 OEM starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Black finish. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models. Use 2 per starter. Each:
$ 2.50
HCP21306 Aftermarket starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Black finish. Fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1996-98 XJ600 Seca II models. Use 2 per starter. Each:
$ 1.50
HCP27308 Aftermarket starter motor mounting FLANGE BOLT, to attach the starter motor end case to the engine. Bright finish. Fits all 1992-95 XJ600 Seca II models. Use 2 per starter. Each:
$ 1.95
XJ650, XJ700, XJ750, and XJ900RK models:
HCP486 Aftermarket starter motor BRUSH HOLDER, fits all XJ650, XJ700, XJ750, and all XJ900 models. Use one per starter, does not include the brushes.
$ 49.95
HCP480 OEM starter motor POSITIVE BRUSH, fits all XJ650, XJ700, XJ750, and all XJ900 models.
$ 21.50
HCP482 OEM starter motor NEGATIVE BRUSH, fits all XJ650, XJ700, XJ750, and all XJ900 models.
$ 21.50
HCP4158 Aftermarket starter motor BRUSH SET, fits all XJ650, XJ700, XJ750, and all XJ900 models. Order one set to do one starter.
$ 21.95
HCP4159 Aftermarket starter motor BRUSH AND PLATE SET, fits all XJ650, XJ700, XJ750, and all XJ900 models. Complete set of two brushes with the mounting plate. Includes the stud insulator bushings set. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 42.95
HCP18274 Aftermarket starter motor COMPLETE REBUILD KIT, fits all XJ650, XJ700, XJ750, and all XJ900 models. Complete set of two brushes with the mounting plate, nose o-ring, case o-rings (2), drive gear bearing and oil seal, end cap bronze bushing, planetary gear collars (2), positive post stud insulators and hardware. All of the items necessary to do a complete starter motor overhaul. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 64.95
HCP6375 Aftermarket starter motor positive brush wiring lead STUD BUSHINGS SET, fits all XJ650, XJ700, XJ750, and all XJ900 models. Complete set of two plastic bushings that insulate the positive brush stud where it goes through the starter case. One set does one starter. NOTE: bushings may differ in appearance from original but are designed to work properly in original starter motors. These bushings are already included in the HCP4159 Brush and Plate Set and the HCP18274 Complete Rebuild Kit listed above.
$ 13.95
HCP3072 OEM starter motor END GEAR CIRCLIP, fits all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Use 1 per starter.
$ 9.95
HCP22885 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Black phosphate coated spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 4.95
HCP23688 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Passivated 400-series stainless spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 5.95
HCP4976 OEM starter motor armature shaft SPACER WASHER, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 1 per starter. This ultra-thin shim “washer” fits on the armature at brush-plate end of the shaft. The larger, thicker washer that fits onto the armature shaft at the “gear end” of the shaft is different and is not currently available.
$ 2.95
HCP2568 OEM starter motor positive brush lead stud INNER NUT, fits all XJ650, XJ700, XJ750, and all XJ900 models. This flanged nut secures the positive brush stud to the motor case.
$ 6.95
HCP315 OEM starter motor positive brush lead stud LOCK WASHER, fits all XJ650, XJ700, XJ750, and XJ900 models.
$ 2.95
HCP916 Aftermarket zinc-plated alloy steel with a natural finish, motor positive brush lead stud LOCK WASHER, fits all XJ650, XJ700, XJ750, and XJ900 models.
$ 1.25
HCP319 Aftermarket 18-8 stainless steel motor positive brush lead stud LOCK WASHER, fits all XJ650, XJ700, XJ750, and XJ900 models.
$ 1.50
HCP321 Aftermarket black oxide-coated alloy steel motor positive brush lead stud LOCK WASHER, fits all XJ650, XJ700, XJ750, and XJ900 models.
$ 1.75
HCP2176 OEM starter motor positive brush lead stud OUTER NUT, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and all XJ900 models, not the same in appearance as original but will work properly. This nut secures the starter motor power cable to the positive brush lead wire stud.
$ 2.95
HCP24035 Aftermarket starter motor positive brush lead stud OUTER NUT, made from 18/8 stainless steel, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and all XJ900 models. This nut secures the starter motor power cable to the positive brush lead wire stud.
$ 1.95
HCP479 OEM starter motor snout-to-engine case O-RING, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 14.95
HCP2320 Aftermarket starter motor snout-to-engine case O-RING, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 5.95
HCP2564 OEM starter motor END CAP O-RING, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per starter.
$ 21.95
HCP18663 Aftermarket starter motor END CAP O-RING, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per starter.
$ 14.95
HCP3079 OEM starter motor CASE BOLT, cinches the end caps together to the center case. Fits all XJ650, XJ700, XJ750, and all XJ900 N, FN, and F models. Use 2 per starter. Bright plated. Some models used black finished bolts. Each:
$ 13.95
HCP15324 Aftermarket starter motor CASE BOLT, cinches the end caps together to the center case. Fits all XJ650, XJ700, XJ750, and all XJ900 N, FN, and F models. This allen-drive, socket head cap screw replaces the original phillips-drive, panhead screw, and is made from a black-oxide coated alloy steel material. Use with the HCP59 lockwasher below. Use 2 per starter. Each:
$ 3.95
HCP59 Aftermarket starter motor case bolt LOCK WASHER, black-oxide coated steel. Use with the HCP15324 case bolt above. Each.
$ 1.00
HCP3080 OEM starter motor-to-engine case SHORT BOLT, to attach the starter motor outer end to the engine case boss, rear position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. Black, flanged hex-head bolt. Some models used natural finished bolts. Each:
$ 3.95
HCP14280 Aftermarket starter motor-to-engine case SHORT BOLT, to attach the starter motor outer end to the engine case boss, rear position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. 18-8 stainless steel, bright finish, hex-head bolt. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 2.95
HCP14281 Aftermarket starter motor-to-engine case SHORT BOLT, to attach the starter motor outer end to the engine case boss, rear position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. 18-8 stainless steel, bright finish, allen-drive bolt matches the style of the side cover bolts. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 1.95
HCP14282 Aftermarket starter motor-to-engine case SHORT BOLT, to attach the starter motor outer end to the engine case boss, rear position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. Black-oxide coated alloy steel, allen-drive bolt matches the style of the side cover bolts. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 1.95
HCP14287 Aftermarket starter motor-to-engine case LONG BOLT, to attach the starter motor outer end to the engine case boss, forward position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. 18-8 stainless steel, bright finish, hex-head bolt. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 3.95
HCP28070 Aftermarket starter motor-to-engine case LONG BOLT, to attach the starter motor outer end to the engine case boss, forward position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. Class 10.0 alloy steel, black finish, hex-head bolt. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 3.95
HCP14288 Aftermarket starter motor-to-engine case LONG BOLT, to attach the starter motor outer end to the engine case boss, forward position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. 18-8 stainless steel, bright finish, allen-drive bolt matches the style of the side cover bolts. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 3.95
HCP14289 Aftermarket starter motor-to-engine case LONG BOLT, to attach the starter motor outer end to the engine case boss, forward position. Fits all XJ650, XJ700, XJ750, and XJ900RK and RL models. Use 1 per starter. Black-oxide coated alloy steel, allen-drive bolt matches the style of the side cover bolts. Note that the original bolt has a flanged head, which is not present on this replacement bolt, so you will need to use one of the washers listed below with this bolt. Each:
$ 4.95
HCP6642 Aftermarket starter motor-to-engine case mounting bolt FLAT WASHER, required for use with any of the aftermarket mounting bolts listed above. Zinc-plated steel. Use 1 per long or short aftermarket bolts. Each:
$ 0.95
HCP6643 Aftermarket starter motor-to-engine case mounting bolt FLAT WASHER, required for use with any of the aftermarket mounting bolts listed above. 18-8 stainless steel with a natural finish. Use 1 per long or short aftermarket bolts. Each:
$ 1.25
HCP25756 Aftermarket starter motor-to-engine case mounting bolt FLAT WASHER, required for use with any of the aftermarket mounting bolts listed above. 316 stainless steel with a natural finish. Use 1 per long or short aftermarket bolts. Each:
$ 1.95
HCP14285 Aftermarket starter motor-to-engine case mounting bolt FLAT WASHER, required for use with any of the aftermarket mounting bolts listed above. Black-oxide coated 18-8 stainless steel. Use 1 per long or short aftermarket bolts. Each:
$ 1.95
HCP14284 Aftermarket starter motor-to-engine case mounting bolt FLAT WASHER, required for use with any of the aftermarket mounting bolts listed above. Black-oxide coated hardened alloy steel. Use 1 per long or short aftermarket bolts. Each:
$ 2.95
XJ1100 and XS1100 models:
HCP481 OEM starter motor POSITIVE BRUSH, fits all XJ1100 and XS1100 models.
$ 34.00
HCP483 OEM starter motor NEGATIVE BRUSH, fits all XJ1100 and XS1100 models.
$ 34.00
HCP4908 Aftermarket starter motor BRUSH SET, fits all XJ1100 and XS1100 models. Order one set to do one starter.
$ 24.95
HCP18275 Aftermarket starter motor COMPLETE REBUILD KIT, fits all XJ1100 and XS1100 models. Complete set of four brushes with the mounting plate, brush springs, nose o-ring, end cap o-ring, case gasket, bearing and oil seals, bushing, collars, positive post stud insulator and washers. All the items necessary to do a complete starter motor overhaul. NOTE: brushes and plate may differ in appearance from original but are designed to work properly in original starter motors.
$ 59.95
HCP2566 OEM starter motor snout-to-engine case O-RING, fits all XJ1100 and XS1100 models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 13.95
HCP21661 Aftermarket starter motor snout-to-engine case O-RING, fits all XJ1100 and XS1100 models. It's a good idea to replace this o-ring whenever the starter motor is removed from the engine before re-installation.
$ 6.95
HCP6841 Aftermarket starter motor END CAP O-RING, fits all XJ1100 and XS1100 models, as well as all of the following engines: 1976-77 XS360 C/D, 1977 XS400 D, 1978-81 XS400 D/E/F/G/SG//H/SH, 1975-76 XS500 B/C, 1977-78 XS500 D/E, 1973-74 TX500, 1977-79 XS750 D/2D/E/SE-31/E_227/SF, 1980-81 XS850 G/SG/LG/H/SH/LH, 1984-87 XV700 Virago, 1981-83, 1988-89 XV750 Virago, 1984-89 XV1100 Virago, 1981-82 XV920 RH/RJ, 1982-83 XV920 J/K/MK, 1984-85 FJ1100, 1986-87, 1989-90 FJ1200, 1985-86 and 1988--92 VMX12 V-Max, 1983-84 and 1989 XVZ12, and 1986-89 XVZ13 models. Use 1 per starter.
$ discontinued
HCP22885 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Black phosphate coated spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 4.95
HCP23688 Aftermarket starter motor END GEAR CIRCLIP, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. Passivated 400-series stainless spring steel. Use 1 per starter. NOTE: on XJ550, FJ600, FZ600, and YX600 starter motors, this is the smaller of the two circlips, located on the very end of the shaft (retaining the drive gear). On XJ650-900 models, it is the only circlip used, and it too is on the very end of the shaft (retaining the drive gear).
$ 5.95
HCP3996 OEM starter motor positive stud NUT, alloy steel with a bright zinc-plated finish, use 2 per starter motor or all XJ1100 and all XS1100 engines. Each:
$ 2.95
HCP16570 Aftermarket starter motor positive stud NUT, 18/8 stainless steel with a bright zinc-plated finish, use 2 per starter motor or all XJ1100 and all XS1100 engines. Each:
$ 1.95
HCP3077 OEM starter motor case LONG BOLT, cinches the end caps together to the center case. Fits all XJ1100 models. Use 2 per starter. Each:
$ 12.95
HCP3701 OEM starter motor cover mounting BOLT, use 2 on all XJ1100 models. Originals were bright plated, these replacements feature a dark phosphate plating. Each:
$ 0.95
HCP13157 Aftermarket starter motor cover mounting BOLT, use 2. Bright plated hex-head 18/8 stainless steel bolt is correct for all for all XJ1100 models. Each:
$ 1.00
HCP2533 OEM starter motor cover mounting BOLT, use 1 on all XJ1100 models. Zinc-plated alloy steel hex-head bolt. Each:
$ 1.95
HCP17146 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Zinc-plated alloy steel hex-head bolt. Each:
$ 1.25
HCP17148 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Bright finish 18/8 stainless steel hex-head bolt. Each:
$ 1.50
HCP17147 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Black-oxide coated alloy steel hex-head bolt as original. Each:
$ 1.75
HCP2424 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Black oxide coated alloy steel socket head, allen-key drive bolt. Each:
$ 1.95
HCP80 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Black oxide coated alloy steel socket head, allen-key drive bolt. Features a small nylon thread patch, making this a self-locking bolt. Each:
$ 1.95
HCP2423 Aftermarket starter motor cover mounting BOLT, use 1 on all XJ1100 models. Bright 18-8 stainless steel socket head, allen-key drive bolt. Each:
$ 1.95
HCP2173 OEM starter motor cover mounting bolt FLAT WASHER, use a total of 3 on all XJ1100 models, original bright finish, each:
$ 1.95
HCP6642 Aftermarket starter motor cover mounting bolt FLAT WASHER, zinc-plated alloy steel with a natural finish, use a total of 3 on all XJ1100 models, each:
$ 0.95
HCP6643 Aftermarket starter motor cover mounting bolt FLAT WASHER, 18-8 stainless steel with a natural finish, use a total of 3 on all XJ1100 models, each:
$ 1.25
HCP25756 Aftermarket starter motor cover mounting bolt FLAT WASHER, 316 stainless steel with a natural finish, use a total of 3 on all XJ1100 models, each:
$ 1.95
HCP14285 Aftermarket starter motor cover mounting bolt FLAT WASHER, black oxide-coated 18-8 stainless steel, use a total of 3 on all XJ1100 models, each:
$ 1.95
HCP14284 Aftermarket starter motor cover mounting bolt FLAT WASHER, black oxide-coated hardened alloy steel, use a total of 3 on all XJ1100 models, each:
$ 1.95
Starter Motor ID Decals:
HCP15132 Aftermarket starter motor case ID DECAL, black foil decal with the brushed silver 4K0-81800-50 wording. This decal is used on all models that have black-painted starter motors. Used on the XJ650, XJ700, XJ750, and XJ900 models.
$ 9.95
HCP15189 Aftermarket starter motor case ID DECAL, black foil decal with the brushed silver 4H7-81800-50 wording. This decal is used on all models that have silver-painted starter motors. Used on the XJ650, XJ700, XJ750, and XJ900 models.
$ 9.95
Starter Motor Rebuild Supplies:
HCP8608 Aftermarket gear and bearing synthetic RED MOLY GREASE. High temperature, water resistant, extreme pressure and high-load strength synthetic organic moly grease is far superior to black moly disulfide (petroleum-based) products. Use on steering neck bearings, wheel bearings, starter motor gears, driveshaft splines, swingarm and final drive bearings. 14 oz. tube.
$ 24.95
cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn't "shed" particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2" wide x 1-foot long strip, enough for polishing many a commutator or contact.
HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12" x 2". Each:
$ 3.50
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP12352 Aftermarket water-soluble (rinse-off) AEROSOL ENGINE DEGREASER and CLEANER, in a handy 13-ounce aerosol can. Each:
$ 24.95
HCP12354 Aftermarket water-soluble (rinse-off) ENGINE DEGREASER and CLEANER, in a 16-ounce non-aerosol can. Best to transfer into an old windex spray bottle (etc.) and use with a spray nozzle. Each:
$ 21.95
Super-Penetrant Fluids and Lubricants:
Sometimes, the toughest part of working on a vehicle is battling the effects of time: seized fasteners, caused by rust, corrosion, and other factors, turns what should be a 5-minute effort into a 50-minute (or more) chore, complete with rounded-off, ruined, or snapped fasteners, e-z outs, heli-coil inserts, and more.........and that's just not right.
While the proper use of our various Anti-Seize products will prevent these nightmares from occurring in the future, you're stuck in the here-and-now, and the best way to handle these obstacles is to have the proper tools at the stand-by; and in the case of fastener seizure, the proper "tool" is a can or two of our SUPER PENETRATING LUBRICANTS at the ready; a couple of squirts, a little bit of time-----perhaps some heat for those really nasty situations----and you're on your way again, hopefully not too much worse for the experience.....
Great for use on all fasteners, fork tube cap bolts, intake and exhaust manifolds bolts, studs, and nuts, lock cylinder tumblers, or anywhere an un-cooperative fastener can be found. Can even be used to help un-seize frozen engines!
Be aware that these products are not your typical, garden-variety, run-of-the-mill "retail" type products; these are designed an used as industrial- and military-strength products, meaning they have special formulations that include a dollop more of the "good stuff" within them to solve the toughest seizure problems imaginable (the "good stuff" ingredients cost more, and it is those compounds that are left out of or reduced in concentration in "retail" level consumer products).
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP10331 Aftermarket standard-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Oil-based lubricant penetrates down into spaces of one-millionth of an inch to handle the most reluctant seizures. Actually dissolves the rust and corrosion that causes the seizure; lubricates and displaces moisture to prevent rust re-formation. This product is what we use and recommend for freeing stuck fork tube cap bolts and other such challenging fasteners.
$ 19.95
HCP11974 Aftermarket super-duty PENETRATING LUBRICANT, in a generous 13-ounce aerosol can. Same as our standard-duty formula above, but also includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. The cat's-meow of penetrating fluids, can even be used to un-seize frozen engines or as an engine assembly lube! This fluid is also a great choice for use as a drive cable lubricant.
$ 20.95
HCP10333 Aftermarket extreme-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Same as our standard-duty formula above, but also includes liquid silicone to enhance and speed up the penetrant action. This product is also an exceptional choice for use as a control-cable lubricant.
$ 22.95
STARTER CLUTCH REBUILD PARTS:
sms6) OEM and aftermarket parts to rebuild your STARTER MOTOR CLUTCH DRIVE. Yamaha used a "centrifugal clutch" type of drive system to engage and disengage the starter motor drive from the engine:
and over time the springs, spring caps, and roller pins that provide the engagement action can fail....which is terrible, as these are a real pain to replace, and always requires the dis-assembly of the upper and lower engine cases:
http://xjbikes.com/forums/threads/xj750-engine-removal-and-split-pictures.38545/
However, there are a few alternative methods that might (or might not) save you some incredible effort and allow you to "dodge a bullet" and repair your starter clutch system in an easier manner; but, the success of such methods really depends upon whether the clutch failure is due to mechanical wear or damage to the pins, caps, or springs (in which case, you MUST somehow get in there and replace those items), or, if the caps and pins are merely "seized" in the starter clutch hub due to accumulated varnish and sludge, etc.----and in such a situation, then you might be able to clean out the mess and restore the clutch to an operational condition.
Methods a) and b) below address the problem of "sludge-seized" component pieces. Method c) deals with the problem of damaged parts. Note that if any of the major components are damaged---the clutch hub, or any idle gears or sprockets---then the engine is going to have to come out and taken apart to allow access to such larger pieces.
a) Pull the starter motor.....or, even better, the alternator shaft housing.......and shoot lots of solvent (seafoam, carb or brake cleaner, etc.) directly onto and into the Starter Clutch Assembly. Then, drain all of your engine oil and refill with fresh oil. Run the engine while on the centerstand until it's warmed up, drain the oil again, and fill with fresh oil. If the starter clutch was just sticking, this method may wash away enough of the accumulated gunk and set you on your way.
b) which in turn spins the another INTERMEDIATE IDLER GEAR attached to the rear side of the STARTER CLUTCH ASSEMBLY.
By the way, if your engine is locked up for some reason (carbs flooded and hydrolocked a cylinder, for example), it's possible that a starter motor in good shape---and backed up by a good battery---can strip out the about two gears, as seen in this very nice thread:
https://www.xjrider.com/viewtopic.php?t=6298
A starter motor that spins, without turning over the engine, is symptomatic of this type of (fortunately) rare problem.
c) This entire "starter clutch assembly" consists of the above intermediate idler gear and a CENTRAL HUB UNIT which contains the centrifugally-operated springs, caps, and roller pins which lock the starter clutch operation to the starter motor. Failure of both the hub unit itself (it can develop hairline---or larger----cracks over time) as well as wear or seizure of the springs, caps, or roller pins accounts for 99.9% of all starter clutch problems and failures.
AND, be aware that a failing battery and/or a starter motor with a shorted winding or excessive carbon build-up on the commutator, or even burnt contacts in the starter solenoid, can reduce current to the starter motor to a point where it can't produce enough torque upon the starter clutch, and thus mimic starter clutch failure symptoms (that "bag of rocks" sound and an engine that doesn't turn over), so be sure to eliminate those as potential problems before digging into your engine!
ALSO, TAKE NOTE OF THIS EXPERIENCE FROM ANOTHER XJ-OWNER:
"If there is not enough grip between the plunger and the roller, it can skip, causing the grinding, clacking noises you hear. I have been told by a Yamaha mechanic with over 20 years experience that it is very possible for some synthetics to greatly increase the chances that this will occur......"
So this weekend I drained the synthetic out, put some cheap 20W50 in, and rode it for a little while. Then I drained the cheap oil out and put Castrol GTX 20W50 in and the starter does not malfunction anymore, not even once! I can't believe it! I guess these bikes were not made to run synthetic---I'm sticking with conventional oil from now on."
c) If none of the above solutions work, then it might be time to do the dirty deed.....the engine will need to come out of the frame and be dis-assembled to access this area. If you read this thread:
http://xjbikes.com/forums/index.php?threads/1700
you'll get a good idea of what challenges you're up against.
By the way, if you do decide to split the engine open and perform open-heart surgery, you might as well replace the primary chain and guide while you're in there, as those are also "wear items" and will cause problems if and when they start failing!
Starter Clutch Components and Operation:
The general layout of the starter motor clutch system is as follows (it differs slightly between the various engine types, but overall, here is what is happening):
a) the starter motor gear operates upon a PRIMARY IDLER GEAR (which is supported on its own shaft)....
b) which in turn spins the another INTERMEDIATE IDLER GEAR attached to the rear side of the STARTER CLUTCH ASSEMBLY.
c) This entire "starter clutch assembly" consists of the above intermediate idler gear and a CENTRAL HUB UNIT which contains the centrifugally-operated springs, caps, and roller pins which lock the starter clutch operation to the starter motor. Failure of both the hub unit itself (it can develop hairline---or larger----cracks over time) as well as wear or seizure of the springs, caps, or roller pins accounts for 99.9% of all starter clutch problems and failures.
d) The "central hub unit" is attached via rubber ABSORBERS operating on the STARTER WHEEL to the starter clutch OUTER COVER, and this outer cover has a DRIVEN GEAR which is operated by the PRIMARY CHAIN, referred to in technical manuals as the "Hy-Vo" chain. Hy-Vo Chain is a unique type of Silent Chain. Hy-Vo stands for High Capacity, High Velocity, and Involute Tooth, and it is a registered trademark of Borg-Warner Automotive, Inc.
http://chain-guide.com/applications/1-6 ... chain.html
e) The starter clutch assembly rides upon the same shaft that drives the alternator.
f) If you are going to have the starter clutch assembly out of the engine and available for rebuild, we suggest that the central hub unit be inspected carefully for any damage or cracks, and replaced if needed. Here is a common problem that you need to look for (scroll down for the image of the cracked hub):
http://xjbikes.com/forums/index.php?threads/starter-clutch.14924/
Also take note that if the hub is not cracked, there is some good advice about re-conditioning the hub that you may wish to follow.
If the hub is secure, then always replace the springs, caps, and pins, as well as the rubber absorbers used within the starter wheel.
http://www.xjbikes.com/forums/threads/complete-xj650-rebuild.81981/page-2#post-500076
Starter Clutch Primary Idler Gear:
HCP8687 OEM starter clutch system PRIMARY IDLER GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 52.95
HCP18661 OEM starter clutch system primary idler gear SHAFT, for all FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 12.95
HCP8688 OEM starter clutch system primary idler gear shaft RETAINER PLATE, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 2.95
HCP2171 OEM starter clutch system primary idler gear shaft retainer plate BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 2.95
HCP24067 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 1.25
HCP24077 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, 6-point hex head 18/8 stainless steel fastener with a bright finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 1.75
HCP24078 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, 6-point hex head 316 stainless steel fastener with a bright finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 1.95
HCP6639 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 1.95
HCP24075 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 2.25
HCP6640 Aftermarket starter clutch system primary idler gear shaft retainer plate BOLT, socket head (hex-key drive) black oxide-coated alloy steel fastener. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 1.95
HCP8689 OEM starter clutch system primary idler gear shaft retainer plate bolt LOCK WASHER, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 4.95
HCP3144 OEM starter clutch system primary idler gear shaft retaining CIRCLIP, for all XJ1100 engines.
$ 3.95
HCP12791 OEM starter clutch bearing housing cover O-RING, for all XJ1100 engines. Use 2 per cover. Each:
$ 5.95
HCP966 OEM starter clutch bearing housing cover MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Use 3 per cover on all XJ1100 engines. Use 3 per cover. Each:
$ 2.50
HCP22253 Aftermarket starter clutch bearing housing cover MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Use 3 per cover on all XJ1100 engines. Each:
$ 1.95
HCP228 Aftermarket starter clutch bearing housing cover MOUNTING BOLT, allen head hex-drive, black-oxide coated. Uses 3 per cover. Fits all XJ1100 models. Each:
$ 1.00
HCP2779 Aftermarket starter clutch bearing housing cover MOUNTING BOLT, allen head hex-drive, black-oxide finish, features self-locking threads. Uses 3 per cover. Fits all XJ1100 models. Each:
$ 2.50
HCP226 Aftermarket starter clutch bearing housing cover MOUNTING BOLT, allen head hex-drive, bright 18-8 stainless steel finish. Uses 3 per cover. Fits all XJ1100 models. Each:
$ 2.00
Starter Clutch Intermediate Idler Gear:
HCP8695 OEM starter clutch system INTERMEDIATE IDLER GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. Comes with the internal bronze bushing.
$ 139.95
HCP8700 OEM starter clutch system intermediate idler gear COLLAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ discontinued
Starter Clutch Complete Hub Unit:
HCP8667 OEM starter clutch complete CENTRAL HUB UNIT, includes the compression springs, caps, and roller pins. For all XJ550 and FJ600 engines.
$ 199.95
HCP8690 OEM starter clutch complete CENTRAL HUB UNIT, this outer housing unit includes the compression springs, caps, and roller pins. For all XJ650 and 1981-83 XJ750 air-cooled engines. NOTE: you can use the stronger XJ700/XJ750-X/XJ900 unit in place of this one for increased durability and more reliable performance.
$ 159.95
HCP23830 Aftermarket starter clutch complete CENTRAL HUB UNIT, this outer housing unit includes the compression springs, caps, and roller pins. For all XJ650 and 1981-83 XJ750 air-cooled engines. NOTE: you can use the stronger XJ700/XJ750-X/XJ900 unit in place of this one for increased durability and more reliable performance.
$ 89.95
HCP8691 OEM starter clutch complete CENTRAL HUB UNIT, this outer housing unit includes the compression springs, caps, and roller pins. For all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F engines. NOTE: you can use this unit in place of the stock XJ650 / 1981-83 XJ750 version for increased durability and more reliable performance
$ 199.95
HCP24017 Aftermarket starter clutch complete CENTRAL HUB UNIT, this outer housing unit includes the compression springs, caps, and roller pins. For all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F engines. NOTE: you can use this unit in place of the stock XJ650 / 1981-83 XJ750 version for increased durability and more reliable performance.
$ 99.95
HCP8707 OEM starter clutch complete CENTRAL HUB UNIT, this outer housing unit includes the compression springs, caps, and roller pins. For all XJ1100 and XS1100 engines.
$ 349.95
Starter Clutch Hub Compression Spring:
HCP8670 OEM starter clutch hub COMPRESSION SPRING, use 3 per clutch, for all XJ550 and FJ600 models, each:
$ 4.95
HCP8692 OEM starter clutch hub COMPRESSION SPRINGS, use 3 per clutch, for all XJ650 and XJ750 models, each:
$ 4.95
HCP8693 OEM starter clutch hub COMPRESSION SPRINGS, use 3 per clutch, for all XJ700, all XJ900RK, RL, N/FN, and F engines, XJ1100, and all XS1100 models. Each: NOTE: you can use this spring in place of the stock XJ650 / 1981-83 XJ750 spring for increased durability and more reliable performance
$ 5.95
Starter Clutch Hub Spring End Cap:
HCP8669 OEM starter clutch hub compression spring END CAP, use 1 per spring, 3 per clutch, for all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, XJ1100, and all XS1100 models. Each:
$ 13.95
Starter Clutch Hub Roller Pin:
HCP8668 OEM starter clutch hub compression spring ROLLER PIN, use 3 per clutch, for all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, each:
$ 4.95
HCP8708 OEM starter clutch hub compression spring ROLLER PIN, use 3 per clutch, for all XJ1100 and XS1100 models, each:
$ 8.95
Starter Clutch Hub Mounting Bolt:
HCP8672 OEM starter clutch hub MOUNTING BOLT, use 3 per clutch, for all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, each:
$ 5.95
HCP10474 Aftermarket starter clutch hub MOUNTING BOLT, use 3 per clutch, for all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, each:
$ 1.95
Starter Clutch Starter Wheel Components:
HCP8673 OEM starter clutch system starter wheel ABSORBER, use 4 per wheel, for all XJ550 and FJ600 engines. Each:
$ 9.95
HCP8697 OEM starter clutch system starter wheel ABSORBER, use 4 per wheel, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. Each:
$ 7.95
Starter Clutch Driven Gear:
HCP8698 OEM starter clutch cover DRIVEN GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ discontinued
HCP3144 OEM starter clutch cover driven gear CIRCLIP, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 3.95
Starter Clutch Primary Drive Chain:
Referred to in the service manuals as "Hy-Vo Chain, the primary drive chains is a unique type of silent-running chain. Hy-Vo stands for High Capacity, High Velocity, and Involute Tooth, and it is a registered trademark of Borg-Warner Automotive, Inc.
http://chain-guide.com/applications/1-6 ... chain.html
HCP7874 OEM starter clutch PRIMARY CHAIN, for all XJ550 models.
$ 329.95
HCP22540 OEM starter clutch PRIMARY CHAIN, for all 1992-98 XJ600 Seca II models.
$ 149.95
HCP7197 OEM starter clutch PRIMARY CHAIN, for all XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models.
$ 89.95
HCP8640 OEM starter clutch PRIMARY CHAIN, for all XJ1100 models.
$ discontinued
Starter Clutch Primary Chain Guide:
This plastic chain guide should always be replaced when the engine is apart. Similar in design and concept to the camshaft drive chain guides, as it ages it gets hard and starts shedding small (or large) chunks of plastic into the engine, some of which invariably end up in the gear shifter drum assembly.....causing you to lose the ability to upshift or downshift into some (or all) of your gears. In fact, if you experience such a shifting problem, and remove the shifter drum and dig out hunks of plastic, this is a sure sign of impending starter primary chain guide failure (followed closely by the failure of the primary chain). Pieces of hard plastic discovered during an oil change may also point to the same problem.
A great visual of this "problem child" part can be seen on the 2nd image down on this page (visual is correct for XJ650-XJ900 engines):
http://www.xjbikes.com/forums/threads/bks-winter-restomod-project-82-xj650-seca.72850/page-7
HCP18662 OEM starter primary chain plastic GUIDE, for all XJ550 and 1984-85 FJ600 engines.
$ 239.95
HCP22539 OEM starter primary chain plastic GUIDE, for all 1992-98 XJ600 Seca II models. NOTE: some original versions of this guide used three mounting bolt "tabs" (and required 3 mounting bolts). This replacement versions only uses two mounting tabs, and thus two mounting bolts (one at each end).
$ 107.95
HCP7551 OEM starter primary chain plastic GUIDE, for all XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: some original versions of this guide used three mounting bolt "tabs" (and required 3 mounting bolts). This replacement versions only uses two mounting tabs, and thus two mounting bolts (one at each end). NOTE: due to the position of the guide, it may be easier to install using aftermarket sockethead bolts (HCP6715 or HCP6716) rather than the original hex-head (HCP4791) bolts.
$ 79.95
HCP8641 OEM starter primary chain plastic GUIDE, for all XJ1100 and XS1100 models.
$ discontinued
HCP4791 OEM starter primary chain plastic guide RETAINING BOLT, use 3 per guide, for all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: some original versions of the guide may have had three mounting bolt "tabs" (and required 3 mounting bolts). The replacement HCP7551 guide only uses two mounting tabs, and thus only two of these mounting bolts are required. Hex-head, black-oxide coated bolt. Each:
$ 4.95
HCP6715 Aftermarket starter primary chain plastic guide RETAINING BOLT, use 3 per guide, for all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: some original versions of the guide may have had three mounting bolt "tabs" (and required 3 mounting bolts). The replacement HCP7551 guide only uses two mounting tabs, and thus only two of these mounting bolts are required. Socket head, hex-drive, black-oxide coated alloy steel, each:
$ 1.75
HCP6716 starter primary chain plastic guide RETAINING BOLT, use 3 per guide, for all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: some original versions of the guide may have had three mounting bolt "tabs" (and required 3 mounting bolts). The replacement HCP7551 guide only uses two mounting tabs, and thus only two of these mounting bolts are required. Socket head, hex-drive, 18-8 stainless steel, bright finish, each:
$ 1.95
HCP2171 OEM starter primary chain plastic guide RETAINING BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish. Use 2 per guide, for all XJ1100 models, each:
$ 2.95
HCP24067 Aftermarket starter primary chain plastic guide RETAINING BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish. Use 2 per guide, for all XJ1100 models, each:
$ 1.25
HCP24077 Aftermarket starter primary chain plastic guide RETAINING BOLT, 6-point hex head 18/8 stainless steel fastener with a bright finish. Use 2 per guide, for all XJ1100 models, each:
$ 1.75
HCP24078 Aftermarket starter primary chain plastic guide RETAINING BOLT, 6-point hex head 316 stainless steel fastener with a bright finish. Use 2 per guide, for all XJ1100 models, each:
$ 1.95
HCP6639 Aftermarket starter primary chain plastic guide RETAINING BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish. Use 2 per guide, for all XJ1100 models, each:
$ 1.95
HCP24075 Aftermarket starter primary chain plastic guide RETAINING BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish. Use 2 per guide, for all XJ1100 models, each:
$ 2.25
HCP6640 Aftermarket starter primary chain plastic guide RETAINING BOLT, socket head (hex-key drive) black oxide-coated alloy steel fastener. Use 2 per guide, for all XJ1100 models, each:
$ 1.95
Starter Clutch Primary Chain Tensioner and Lubrication:
NOTE: XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, and 1986-90 YX600 Radian engines can make a particular type of “quiet” rhythmic, metallic knocking sound from the top end, which will disappear as rpm’s increase………..this is typically caused by the primary chain (inside the engine) which can “flop” around a bit at low rpm’s due to low oil pressure (oil pressure is used to tension this chain). It’s nothing to worry about.
HCP13969 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian engines. O-ring is not included and should be ordered separate.
$ 139.95
HCP25652 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all 1992-98 XJ600 Seca II engines. O-ring is not included and should be ordered separate.
$ 44.95
HCP5400 OEM starter chain and guide oil spray nozzle O-RING, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II, and 1992-2002 XJ600 Euro models.
$ 4.95
HCP20977 Aftermarket starter chain and guide oil spray nozzle O-RING, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II, and 1992-2002 XJ600 Euro models.
$ 2.95
HCP20306 OEM primary chain TENSIONER, for all XJ550 and 1984-85 FJ600 engines.
$ 57.95
HCP13977 OEM primary chain tensioner OIL DELIVERY PIPE, for all XJ550, 1984-85 FJ600, and 1992-98 XJ600 Seca II engines.
$ 32.95
HCP19890 OEM primary chain tensioner SPRING, for all XJ550 and 1984-85 FJ600 engines.
$ 5.95
HCP19892 OEM primary chain tensioner PLUNGER, for all XJ550 and 1984-85 FJ600 engines.
$ 27.95
HCP10233 OEM primary chain tensioner oil delivery pipe O-RING, use 1 per pipe on all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II engines.
$ 3.95
HCP20976 Aftermarket primary chain tensioner oil delivery pipe O-RING, use 1 per pipe on all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II engines.
$ 2.50
HCP3412 OEM primary chain tensioner oil delivery pipe copper CRUSH WASHER. Use 2 per tube on all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II, and 1992-2002 XJ600 Euro engines. Each:
$ 2.95
HCP21341 Aftermarket primary chain tensioner oil delivery pipe copper CRUSH WASHER . Use 2 per tube on all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II, and 1992-2002 XJ600 Euro engines. Each:
$ 2.95
HCP10232 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. O-ring is not included and should be ordered separate.
$ 79.95
HCP26174 Aftermarket starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. O-ring is not included and should be ordered separate.
$ 39.95
HCP10233 OEM starter chain and guide oil spray nozzle O-RING, use 1 per engine an all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 3.95
HCP20976 Aftermarket starter chain and guide oil spray nozzle O-RING, use 1 per engine an all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 2.50