1997 XJ600 diversion rebuild

[paul71]

Hello everyone,

I purchased a non running 600 a few months back with a plan to bring it back to life. I completely stripped the bike as I wanted to repaint the frame, throw the wire loom as it's been butchered and do lots of cleaning.

Anyway three months on and the frame is painted a dark metallic green as is the swing arm. I managed to pick up a very cheap 15000 mile engine, a very good condition loom and various other bits. The bike is virtually wired up, the engine has been painted and is in the frame and the wheels are on (although not painted yet) so I can roll it in and out of the garage.

I'm currently trying to get her to crank but not having much luck. I bought a new starter solenoid to eliminate the old battered one and I also bought a right switch gear as the old one was beyond repair. If I cross the solenoid points she cranks and sounds very healthy but nothing off the button. I'm in the process of carrying out tests to see if I can identify the fault but I seem to go round in circles. I'll post some pics once I find a hosting site to upload them to. Once she is up and running I can then concentrate on the plastics etc.

[ianp]

Have you checked the corrosion on the blue wire that goes into the relay under the right hand side panel. It's a common Diversion fault that describes the symptoms you have. Mine looked OK on first inspection but was corroded inside really badly. I pushed a panel pin as a temporary measure and that fixed it (just realised its still there 15,000 miles later and I've sold the bike)

Good luck,

Ian

[paul71]

Hello mate,

Lol that's some temporary fix.

Yes I found my wire had been repaired at some point. I pushed the metal connector back in to the block but can't be certain if it's making contact. Seems far enough in.

[m40man]

Hi - Be sure to make certain of that dodgy connection - I'd be inclined to run a bypass wire either side of the connector to be sure. It's known locally here as the blue wire of death!

[paul71]

Cheers for the input guys. Well after three days of continuity tests, plugging and unplugging connectors, checking wires etc etc, I got it to crank off the button. Traced the fault back to my new starter solenoid. I can now get on with the build at last. Yesterday I was scrapping the bike, but I'll keep it now lol.