Just some problems

[bbaldwin84]

Ok well first of all my headlight and Tach choose to work when they want to. My bike doesn't seem to be charging either. Also the bike seems to be very hesitant when first taking off, but will continue to pull harder through higher RPM's and run smoother. Any ideas ??? HAHA

[tarzan]

I have two xs's in my garage right now.One has that same problem.There is some good info in therepair forum section
that explains how to test your regulator and alternator.But if it is intermittant it is probably a bad ground or connection in a connector.The one I'm currently working on had a melted connector behind the fuse panel(you have to unbolt the panel to get at it).I hear that is a common area for problems.I also foumd I have a bad regulator.
When your alternator dont work on an XS your tach wont work either.And your headlight probably wont either.

[jjwaller]

Bad News

Time to go through every electrical connector pin and individual wire terminations. ESPECIALLY Grounds!!!!
Take apart every plug and fitting on the bike and Clean them thoroughly.
Takes a while, and is a royal pain, But,
that sounds like your problems.
Depending on how much use the carbs have had lately, you might need to clean them too! However start with the electrical. That is definitely the tach and lights. Probable running too.

[bbaldwin84]

yea

Yea I took apart the side to get at the connector and the plug is very clean, still has some eletrical grease on it, no melted wires that I can see. So I assume its the regulator? It def isn't charging because I had to pop start it twice today haha. Sometimes the Tach works by itself, sometimes the headlight works by itself, and sometimes they are both on together. I guess I have to do some testing.

[bbaldwin84]

I know the carbs are newly rebuilt, but the guy said they may have to be tuned. What is Color tuning?

[tarzan]

I would definitely test first.I wouldnt assume it is the regulator unless you are sure, because if it is the regulator it shouldnt charge intermttantly.

[jjwaller]

Doesn't understand

Originally posted by bbaldwin84
Yea I took apart the side to get at the connector and the plug is very clean, still has some eletrical grease on it, no melted wires that I can see. So I assume its the regulator? It def isn't charging because I had to pop start it twice today haha. Sometimes the Tach works by itself, sometimes the headlight works by itself, and sometimes they are both on together. I guess I have to do some testing.

You need to clean every single connector and termination on the bike. One or more of the terminals or pins somewhere is causing the problem due to corrosion.
Take apart every multi-pin connector.
Take apart every single bullet connector.
Take loose every ring terminal ground connector. If you do this, your charging, lights, and probably running problems will be solved. By cleaning, I mean use abrasives! The connectors and places they connect to(grounds) must be shiny,
i.e. look like new.
Like I said, pain the A**, but should last for another few decades.
Good luck

[bbaldwin84]

What about the purple grease stuff? is that to be cleaned off also?

[MotoMartin]

Check the fuse box, that is a weak point on these bikes. The connections sometimes get hot and melt the plastic making the fuses loose, giving intermittent power like your problems. Mine once lost all power on the freeway during rush hour. I have since removed the stock fuse box and replaced it with automotive "plug in" type fuses. The bike has been far more reliable since making the change.

[MotoMartin]

Also for the bike not recharging the battery, check the output of the generator. Take the seat off, and with the bike running, put a volt meter on the neg and pos battery terminals, at 2,000 rpm the output should be 14.5 volts. If it's about 12 or 13 volts replace the generator, I bought one off ebay for about $20. For a long time before that I had to recharge the battery every couple of days.
Changing the fuse box and the generator made a huge difference in the reliability and dependability of my XS.

[bbaldwin84]

The fuse box seems clean also, no melted anything and the connections have a little of that purple grease stuff on it haha.

[Wildkat]

Helpful link

Originally posted by bbaldwin84
I know the carbs are newly rebuilt, but the guy said they may have to be tuned. What is Color tuning?

Colortuning
A very helpful tool, indeed...

As for the purple grease... dielectric grease, maybe?

[bbaldwin84]

Ok so I checked all the white wires, all reading the same ohms, the meter I'm using has an adjustable ohm knob so its hard to say what the exact reading is. the green is registering higher ohms than the brown. also, it looks like someone has cleaned all connections, and actually replaced the block with the three white wires coming from the case, but for some reason there is also a yellow wire that has been capped off, not sure where it is supposed to go if anywhere. I did the Battery terminal test and had 12V at idle and 12V while reving, no change at all.

[tarzan]

With the bike off,disconnect the connector with the briown and green wire.Then rig up a wire from ground (bare metal)to one of
the wires.Then connect another wire to the pos side of your battery.You will have the other end of this pos wire in your hand.Now start your bike.While it is running touch the pos wire to the other wire in the connector.If your light comes on and your tach all of a sudden works,then your regulator is bad. By the way you need to be jumping the side of the connector that has the wires going down towards the alternator.

[bbaldwin84]

Ok, first which part of the connector, the one with the ohm readings or the other side? and what is jumping mean....and again which side of the white wire connector, the one with the readings or the other?

Thanks Again.