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SECTION D:
ELECTRICAL SYSTEM:
--Electrical System Overview.
ELECTRICAL SYSTEM OVERVIEW:
Electrical problems can be terribly difficult to diagnose properly. Electrical and fuel-related problems manifest themselves in the same ways: hard starting, mis-firing, poor performance, back-firing, etc.
Although the electrical systems on XJ bikes are fairly durable, there are a number of known, common problem areas on these bikes, which are compounded by the fact that these bikes are 25+ years old.
The fusebox is the most critical area: the stock one may have been adequate in 1981, but it's now old, outdated, and ready for the dust-bin of history. We carry replacement ATC-style fuseboxes and in-line fuse holders which allow you to easily upgrade your original.
The generator brushes wear down over time, change their electrical characteristics as they age, and need periodic replacement. They are available as complete brushes with holder assemblies, or brushes only. By the way, in a technical sense, your bike is really equipped with an Alternator, not a Generator (as Yamaha calls it), since the output of that electrical-generating device is an alternating (AC) electrical current, which is then rectified into a direct (DC) current via---you guessed it---the rectifier section of your Regulator box......
Anyway: finally, in a general electrical system sense, the wiring harness on your bike is getting old---and like most vehicle wiring harnesses from this era, they aren't (and never were) the most robust things ever made. Corrosion, weak connectors, and other assorted issues will cause you all sorts of headaches and the agony of electrical troubleshooting nightmares if not addressed and remedied.
An exceptional write-up on the electrical system on XJ-series bikes---the good, the bad, and the ugly---can be found at:
http://web.archive.org/web/20071214...ies.com/MotorCity/Speedway/7795/xjfaqbig.html
I highly recommend that you visit that site and PRINT OUT the FAQ (you never know when a web page might disappear from the web), as it is the "Electrical Bible" for XJ owners!
And understanding the importance of (and how to measure) voltage drops in circuits will go a long way to helping you successfully diagnose and solve electrical problems on your bike:
http://www.motorcycleproject.com/text/volt_drop_test.html
and here’s an easy-to-understand guide to how to perform a voltage-drop test:
http://www.agcoauto.com/content/news/p2_articleid/330
Corrosion on wires (the greenish "skin" that forms on exposed wire) is a real deal-killer when it comes to transmitting electricity properly...............and here's how to make it go away:
www.instructables.com/id/How-to-perfectly-clean-wires-in-minutes
SECTION D:
ELECTRICAL SYSTEM TOOLS:
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).
$ 89.95
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%.
$ 89.95
HCP10589 Aftermarket TIMING LIGHT, inductive pickup 12V powered stroboscopic timing light is used to check the proper functioning of your ignition system at the pick-up coils. Alligator clips for easy power hook-up to the battery, and a clamp-over inductive feed clips over the #1 plug wire. Super-bright xenon-bulb makes daytime use possible.
$ 49.95
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........
$ 18.95
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........
$ 14.95
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.
$ 79.95
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/
$ 49.95
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!
$ 79.95
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.
$ 89.95
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.
$ 69.95
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.
$ 24.95
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.
$ 37.95
Electrical System Chemicals and Supplies:
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.
$ 4.95
HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 21.95
NOTE: the following 2 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.
$ 24.95
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.
$ 6.95
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:
$ 4.95
NOTE: the following 3 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.
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.
$ 12.95
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.
$ 12.95
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.
$ 14.95
HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 8.95
HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 16.95
Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.
HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 7.95
HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 7.95
HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 7.95
HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 7.95
et26) Aftermarket electrical device SWITCH LUBRICANT is a specially formulated, electrically non-conductive penetrating lube that is recommended on control switch turn signal contacts and headlight switching contacts. 10-gram squeeze tube has applicator tip for precision use.
HCP14066 Aftermarket tube of electrical SWITCH LUBRICANT.
$ 16.95
et27) Aftermarket electrical INSTRUMENT OIL is a highly refined light oil for use on speedometer heads, tachometers, gauges, mechanical clocks, etc. Will not congeal even at 50-below-zero! Extra-slow rate of evaporation makes sure that it provides lubrication for a long, long time. 1-ounce pen has an applicator needle tip for precision use.
HCP20852 Aftermarket hi-performance INSTRUMENT OIL, comes in a handy applicator pen. Oil-based triple-processed lubricant eliminates contaminants that would cause gumming or corrosion product is what we use and recommend for freeing stuck fork tube cap bolts.
$ 37.95
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.
$ 9.95
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.
$ 13.95
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:
$ 3.95