Tach & signals quit

[jetmechmarty]

Due to my constant traveling, I put my bike in the shop. Long story short, it was gone for almost a year. I'm going home this week and I want to ride while the weather holds.

The new issue is electrical. I start the bike and sometimes the tach isn't working. The turn signals don't work either. I believe the backlights in the clocks are off. The headlight is on and appears to increase intensity with RPM increase. I go to tinker with it and everything starts working again.

Do any of you have an educated guess where my loose connection is?

Thanks!

[CatatonicBug]

Check the big white connector behind the fuse block. Mine had similar issues until I realized that the corrosion in that connector had caused sufficient heat to melt the plastic of the connector, then short out the other wires. If that is your problem, Geezer sells the replacement connectors.

[Cobia]

Ditto with Bug. But also check all the connectors in your headlight bucket. Those get corroded as well.

[jetmechmarty]

Is this Geezer's site?
Oregon Motorcycle Parts

I'll check that connector first, when I get home.

[DGXSER]

Yes, that is Geezer's site.

[bikerphil]

You can also eliminate that alternator plug completely and have hard wire connections. I've done that to a few XS's, plug never gets hot anymore.

Marty, do you still have the old style glass fuses?

[jetmechmarty]

I still have the glass fuse box. I have not touched it. I have one of TC's boxes on hand.

Is the alternator plug up behind the fuse box?

[natemoen]

Don't know where the plug is for sure but just follow the wires from the alt cover.

I would switch out that fuse block for sure. Those clips get really loose.

[DGXSER]

Marty,

Yes, the alternator connection being discussed is between the battery box and the bracket the fuse box is mounted onto. Easiest way to get to it is to pull the three screws attaching the mounting bracket the fuse box attaches to, and the connector from the turn signal flasher, and other components so you can pull the bracket aside.

There are three separate connectors back there. Ther larger one is the alternator, but may as well check and clean all three while your in there.

[jetmechmarty]

I found it. A loose fuse. Imagine that!

[DGXSER]

Still running the glass fuses?? Yeah....imagine that!!.

[jetmechmarty]

glass fuses

The fuse box has lasted 30 years. On my XS650, I replaced the glass fuse box with a new one just like it. If it lasts another 30, I'll be past 80 years old.

In this case, I think I'll go with the spade fuses because I have one and expect I can make a nice clean installation.

[Poprock]

Fuse box is good. Get some DeOxit or other contact cleaner, use it on every connector in the harness. Then fill the plugs with dielectric grease and put 'em back together. Make sure all your ground connections are clean as well. Did that on mine, signals, tail lights, running lights, headlight all got brighter with each step. Engine even ran smoother and started quicker. If you grease the connections, you won't have to clean them again for a long time.