starting switch wiring question

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  • PMKXS11
    Truly XSive
    • Mar 2013
    • 100
    • Rockford, Il.

    #16
    Oh, and out of the TCI I have a black/white tracer, white/red tracer, and red/yellow tracer that aren't hooked up to anything.
    '79 Yamaha XS11 SF (project)
    '11 Harley Nightster (street)
    '03 KTM 125sx (dirt)
    '03 Suzuki GSXR-600 (track)
    '73 Jawa Californian (collecting dust)

    Comment

    • crazy steve
      XS-XJ Guru MODERATOR
      • Jan 2009
      • 7932
      • Beautiful outer Yelm, WA

      #17
      The white/red and red/yellow are both for the ballast resistor bypass circuit, the black/white is for the tipover switch.
      Fast, Cheap, Reliable... Pick any two

      '78E original owner - resto project
      '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
      '82 XJ rebuild project
      '80SG restified, red SOLD
      '79F parts...
      '81H more parts...

      Other current bikes:
      '93 XL1200 Anniversary Sportster 85RWHP
      '86 XL883/1200 Chopper
      '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
      Cage: '13 Mustang GT/CS with a few 'custom' touches
      Yep, can't leave nuthin' alone...

      Comment

      • PMKXS11
        Truly XSive
        • Mar 2013
        • 100
        • Rockford, Il.

        #18
        Originally posted by crazy steve
        Did it work before you wired in the Suzuki switch? If it did, there's a problem in the switch. Make sure you have full power through the switch in any case. If you have battery voltage on the red/white at the coils and battery voltage on the red/white at the TCI with the kill switch closed and the ignition 'on', then the problem is in either the pickup coils or the TCI on the low voltage side of the circuit, or bad secondary coils in the coils (unlikely, but it would pay to check just to eliminate this).
        I got the bike to run a long time ago, then took it all apart, did my frame and engine mods and now I'm reassembling it.

        I have battery voltage at the red/white at the coils and at the TCI. My red/white leaves the Suzuki switch, and splits in two, one end feeding the TCI and the other to the coils. I also have 12V at the gray and orange on the other ends of the coil.

        When I open the kill switch, I lose voltage to the coils and TCI, working as it should. I did not check whether I lose voltage to the orange(left) and gray(right) as well, but I would think so.

        I'm going to leave the battery on the charger while I'm at work, I'm sure all the cranking drained it a little. I will check the secondary resistance on the coils after work.

        Just to be certain, I have the red/white going to the two inside posts on the coils, and the orange(left) and gray(right) on the outside. Is this correct?

        how they are mounted:
        Last edited by PMKXS11; 12-03-2014, 03:47 PM.
        '79 Yamaha XS11 SF (project)
        '11 Harley Nightster (street)
        '03 KTM 125sx (dirt)
        '03 Suzuki GSXR-600 (track)
        '73 Jawa Californian (collecting dust)

        Comment

        • crazy steve
          XS-XJ Guru MODERATOR
          • Jan 2009
          • 7932
          • Beautiful outer Yelm, WA

          #19
          Polarity on the coils (which terminal gets the red/white or gray/orange) shouldn't make any difference, but you may want to check with the manufacturer. If the terminals are marked + and -, connect the red/white to the + just to be safe.
          Fast, Cheap, Reliable... Pick any two

          '78E original owner - resto project
          '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
          '82 XJ rebuild project
          '80SG restified, red SOLD
          '79F parts...
          '81H more parts...

          Other current bikes:
          '93 XL1200 Anniversary Sportster 85RWHP
          '86 XL883/1200 Chopper
          '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
          Cage: '13 Mustang GT/CS with a few 'custom' touches
          Yep, can't leave nuthin' alone...

          Comment

          • PMKXS11
            Truly XSive
            • Mar 2013
            • 100
            • Rockford, Il.

            #20
            http://prestoliteperformance.com/med...403_140404.pdf

            This is what I found. (NOTE after step 12) Polarity does not matter.

            Next step is to check the secondary resistance? Then if that is ok, what next?
            '79 Yamaha XS11 SF (project)
            '11 Harley Nightster (street)
            '03 KTM 125sx (dirt)
            '03 Suzuki GSXR-600 (track)
            '73 Jawa Californian (collecting dust)

            Comment

            • crazy steve
              XS-XJ Guru MODERATOR
              • Jan 2009
              • 7932
              • Beautiful outer Yelm, WA

              #21
              I'd suggest checking the secondary at the plug caps, that should tell you if the coils, wires and caps are good. If the secondary resistance checks good, you can test the coils by 'flashing' the orange or gray wires to ground. This should generate a spark at the spark plug. If you get spark, then the problem is in the TCI or it's connections, or the pickup coils.
              Fast, Cheap, Reliable... Pick any two

              '78E original owner - resto project
              '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
              '82 XJ rebuild project
              '80SG restified, red SOLD
              '79F parts...
              '81H more parts...

              Other current bikes:
              '93 XL1200 Anniversary Sportster 85RWHP
              '86 XL883/1200 Chopper
              '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
              Cage: '13 Mustang GT/CS with a few 'custom' touches
              Yep, can't leave nuthin' alone...

              Comment

              • donebysunday
                XS-XJ Guru
                • Oct 2012
                • 1737
                • New Berlin, Wi.

                #22
                Dang that's puurddy. Nice work !

                Originally posted by PMKXS11
                I got the bike to run a long time ago, then took it all apart, did my frame and engine mods and now I'm reassembling it.

                I have battery voltage at the red/white at the coils and at the TCI. My red/white leaves the Suzuki switch, and splits in two, one end feeding the TCI and the other to the coils. I also have 12V at the gray and orange on the other ends of the coil.

                When I open the kill switch, I lose voltage to the coils and TCI, working as it should. I did not check whether I lose voltage to the orange(left) and gray(right) as well, but I would think so.

                I'm going to leave the battery on the charger while I'm at work, I'm sure all the cranking drained it a little. I will check the secondary resistance on the coils after work.

                Just to be certain, I have the red/white going to the two inside posts on the coils, and the orange(left) and gray(right) on the outside. Is this correct?

                how they are mounted:
                76 XS650 C ROADSTER
                80 XS650 G Special II
                https://ibb.co/album/icbGgF
                80 XS 1100 SG
                81 XS 1100LH/SH DARKHORSE
                https://tinyurl.com/k6nzvtw
                AKA; Don'e, UD, Unca Don'e

                Comment

                • PMKXS11
                  Truly XSive
                  • Mar 2013
                  • 100
                  • Rockford, Il.

                  #23
                  Thanks!

                  Secondary resistance on the coils is 30.70Kohm on the left, 31.23Kohm on the right. "Flash" test produced a spark.

                  My battery has 12.7V at the battery, but it drops to 9.8V when it is cranking, so that would definitely not allow the TCI to fire. So I swapped batteries from my track bike... I didn't notice I reversed the poles My TCI is good as dead, right?
                  '79 Yamaha XS11 SF (project)
                  '11 Harley Nightster (street)
                  '03 KTM 125sx (dirt)
                  '03 Suzuki GSXR-600 (track)
                  '73 Jawa Californian (collecting dust)

                  Comment

                  • crazy steve
                    XS-XJ Guru MODERATOR
                    • Jan 2009
                    • 7932
                    • Beautiful outer Yelm, WA

                    #24
                    Originally posted by PMKXS11
                    ...My battery has 12.7V at the battery, but it drops to 9.8V when it is cranking, so that would definitely not allow the TCI to fire. So I swapped batteries from my track bike... I didn't notice I reversed the poles My TCI is good as dead, right?
                    Maybe, and it may not have done your regulator any good either. If you reconnected the battery right and you still have no spark, yeah, the TCI is likely dead.
                    Last edited by crazy steve; 12-04-2014, 11:08 AM.
                    Fast, Cheap, Reliable... Pick any two

                    '78E original owner - resto project
                    '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
                    '82 XJ rebuild project
                    '80SG restified, red SOLD
                    '79F parts...
                    '81H more parts...

                    Other current bikes:
                    '93 XL1200 Anniversary Sportster 85RWHP
                    '86 XL883/1200 Chopper
                    '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
                    Cage: '13 Mustang GT/CS with a few 'custom' touches
                    Yep, can't leave nuthin' alone...

                    Comment

                    • PMKXS11
                      Truly XSive
                      • Mar 2013
                      • 100
                      • Rockford, Il.

                      #25
                      ****

                      Well looks like I'm on the look for a new TCI now. Was not getting spark after switching it back.
                      '79 Yamaha XS11 SF (project)
                      '11 Harley Nightster (street)
                      '03 KTM 125sx (dirt)
                      '03 Suzuki GSXR-600 (track)
                      '73 Jawa Californian (collecting dust)

                      Comment

                      • PMKXS11
                        Truly XSive
                        • Mar 2013
                        • 100
                        • Rockford, Il.

                        #26
                        Found this, I need an analog meter to test this, right? Tried with a digital meter and am getting about 10.8v but not much of a swing.
                        '79 Yamaha XS11 SF (project)
                        '11 Harley Nightster (street)
                        '03 KTM 125sx (dirt)
                        '03 Suzuki GSXR-600 (track)
                        '73 Jawa Californian (collecting dust)

                        Comment

                        • crazy steve
                          XS-XJ Guru MODERATOR
                          • Jan 2009
                          • 7932
                          • Beautiful outer Yelm, WA

                          #27
                          You can check this with a digital meter if it has a 'bar graph' readout in the display (the dotted line in the display as seen in the last pic here...
                          http://www.xs11.com/forum/showthread.php?t=35338).
                          Fast, Cheap, Reliable... Pick any two

                          '78E original owner - resto project
                          '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
                          '82 XJ rebuild project
                          '80SG restified, red SOLD
                          '79F parts...
                          '81H more parts...

                          Other current bikes:
                          '93 XL1200 Anniversary Sportster 85RWHP
                          '86 XL883/1200 Chopper
                          '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
                          Cage: '13 Mustang GT/CS with a few 'custom' touches
                          Yep, can't leave nuthin' alone...

                          Comment

                          • PMKXS11
                            Truly XSive
                            • Mar 2013
                            • 100
                            • Rockford, Il.

                            #28
                            getting 9.9v to 10.6v swing across both. How do I test the pick up coils?
                            '79 Yamaha XS11 SF (project)
                            '11 Harley Nightster (street)
                            '03 KTM 125sx (dirt)
                            '03 Suzuki GSXR-600 (track)
                            '73 Jawa Californian (collecting dust)

                            Comment

                            • crazy steve
                              XS-XJ Guru MODERATOR
                              • Jan 2009
                              • 7932
                              • Beautiful outer Yelm, WA

                              #29
                              All you can check on the pickup coils is the ohms through them. You're looking for 720 ohms, +/- 20%, so between 580 and 860 is acceptable. I like to check at the TCI, that way you also 'prove' the plug connector in between. You also might want to lift the wire to the neutral light switch off if you get a bad reading, this has been known to short out the pickup wires.

                              But if you're getting a 'swing' on the meter at the gray/orange wires on the coil when turning the motor over, that means the TCI is working; you should be getting spark. Are you sure this isn't a fuel issue?...
                              Fast, Cheap, Reliable... Pick any two

                              '78E original owner - resto project
                              '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
                              '82 XJ rebuild project
                              '80SG restified, red SOLD
                              '79F parts...
                              '81H more parts...

                              Other current bikes:
                              '93 XL1200 Anniversary Sportster 85RWHP
                              '86 XL883/1200 Chopper
                              '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
                              Cage: '13 Mustang GT/CS with a few 'custom' touches
                              Yep, can't leave nuthin' alone...

                              Comment

                              • PMKXS11
                                Truly XSive
                                • Mar 2013
                                • 100
                                • Rockford, Il.

                                #30
                                No fuel, carbs aren't hooked up. I'm not getting spark. I was going to see if I could get the bike to fire first, then worry about the carbs.

                                0.725Kohm @ the lower pick up coil, 0.733Kohm at the upper, so those look ok.
                                I noticed if I moved the advance by hand, the reading jumps to 31.50Mohm
                                '79 Yamaha XS11 SF (project)
                                '11 Harley Nightster (street)
                                '03 KTM 125sx (dirt)
                                '03 Suzuki GSXR-600 (track)
                                '73 Jawa Californian (collecting dust)

                                Comment

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