And suddenly there was no spark...

vorhese · New Member Joined: Jun 11, 2006 Posts: 8

So I spent 4 weeks of spare moments to find an electrical connection problem on my 81 XS650. Then the bike ran great! For one whole day. I was going to Oakland on the Bay Bridge and my bike just died. That was a miserable experience.

It's got juice, the lights work, but I'm not getting any spark. They were new plugs, but I put in new ones just in case. Still nothing. I checked all my connections, cleaned them. I don't see any grounds disconnected. My fuses are all good. I did recently replace the key ignition switch, but that turns the power on to the rear light just fine (headlamp is on it's on circuit). I think I've narrowed it down to a bad coil or bad run/stop switch. I'm a complete novice with electrical and can't seem to make any sense of the wiring diagrams or tests in the books. I tried searching on the forums but can't seem to find anything to help me.

a) How do I check the Run/Stop switch?
b) How do I check the coils? They are aftermarket hotter coils.
c) What else could it be?

It's one thing after another with this bike suddenly.

EDIT: I got ahold of a spare Kill Switch and that didn't help. Now I'm thinking it's coils.

xsjohn

Check Pickup coil on the stator. And mainly the TCI box. This forum should have plenty of info on these problems. It's always good to have a spare TCI box and other electrical stiff that can always be sold later. TCI is easy to plug it in under the left cover just below the seat to test without having to remove the existing one. I carry an extra TCI wrapped in foam in my fairing but luckly have never needed it. Coil can be read with an OHM meter. Check manual. Clean all electrical connections including the larger plugs and use Dielectric Grease on them after cleaning. Watch Ebay for some good deals on electrical spares. These parts just become more valuable as time goes on. Electrical is worse than a hemroid but you will get it. Good luck.

John

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

On mine the cause was old solder joints in the TCI box. If you are a patient - just pull the box off - remove the circuit board - and CAREFULLY resolder the joints on the circuit board. Watch the HEAT - re-solder don't boil the joints.

Did mine - and problem never came back.

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