Voltage loss

[red bandit]

The positive battery cable goes to the solenoid. At the crimp at the solenoid there is a red power wire (to the key switch) that has a plug about 2 inches away. I have the same voltage there in and out as the battery. The red power wire at the plug going to the key switch has 0.2 voltage loss. Is there any crimp or connection between the two? I also have 0.1 voltage loss from the switch to the spade ignition fuse. Total voltage loss at the ign. coils is 0.3. I have cleaned all the plugs with electronic cleaner and taken the key switch apart and cleaned it as well. Is this much voltage loss something to worry about? Should I have the same volts at the ign. coils as at the batt?

[IanDMacDonald]

The positive battery cable goes to the solenoid. At the crimp at the solenoid there is a red power wire (to the key switch) that has a plug about 2 inches away. I have the same voltage there in and out as the battery. The red power wire at the plug going to the key switch has 0.2 voltage loss. Is there any crimp or connection between the two? I also have 0.1 voltage loss from the switch to the spade ignition fuse. Total voltage loss at the ign. coils is 0.3. I have cleaned all the plugs with electronic cleaner and taken the key switch apart and cleaned it as well. Is this much voltage loss something to worry about? Should I have the same volts at the ign. coils as at the batt?

Ideally, you would want source voltage. But, the wires are no-doubt corroded over the years. What you can do is what's referred to a coil relay mod. This sends source voltage straight to the coils.

[motoman]

The positive battery cable goes to the solenoid. At the crimp at the solenoid there is a red power wire (to the key switch) that has a plug about 2 inches away. I have the same voltage there in and out as the battery. The red power wire at the plug going to the key switch has 0.2 voltage loss. Is there any crimp or connection between the two? I also have 0.1 voltage loss from the switch to the spade ignition fuse. Total voltage loss at the ign. coils is 0.3. I have cleaned all the plugs with electronic cleaner and taken the key switch apart and cleaned it as well. Is this much voltage loss something to worry about? Should I have the same volts at the ign. coils as at the batt?

Answer to last two questions is YES/YES. I seriously suggest the stop/run switch be removed from bars, taken apart and clean the contacts. This switch completes the running circuit and IS a common location for voltage loss.

[red bandit]

I cleaned everything some years ago. I'll clean the kill switch next. May take me a few days to get to it. Thanks.

[jetmechmarty]

In the aircraft industry, wires, contacts, and pins are all plated to prevent corrosion. Your motorcycle was not designed for 40+ years of service. Yes, your problem is likely corrosion. That Moto Gadget M-Unit is looking more and more attractive.

[red bandit]

The switch looked good but I wire brushed it any way. It looks like the single plug/red wire by the battery/solenoid and the plug that goes to the switch both have bad connection in the crimps. Can I use spade connectors from the hardware store or what do you suggest?

[DiverRay]

Check with Geezer, and his site,http://oregonmotorcycleparts.com/connectors.html. you can get the correct connectors that will fit as new. If you check, the 1/4" faston connectors will work for most of the flat connections.

[red bandit]

Are you saying his spade connectors will fit in the 11's plastic plug? Or should I buy his plastic plug also. That he is out of the 3 and 4 prong.

[DiverRay]

The spade connector will NOT fit in the connector, but those from Geezer WILL. If your plastic is still good, you can buy just the male and female connectors from him. If the plastic is starting to crack, buy the connectors and have the new plastic on order. It's not that hard to change them out after the install.

[jetmechmarty]

Sparckmoto.com is another source of connectors and pins. You'll need an open barrel crimper.

[dansmith65]

You might be able to clean the connectors by soaking in vinegar: https://youtu.be/xkw_52rFHU8

[red bandit]

I ordered the connectors from Geezer. As far as the open barrel crimper. Would 14-24 awg be a good choice?

[DiverRay]

Yes, as the "large" wires on the bike are 16, except for the red/white battery to relay. I think that is a 12. Battery to ground and hot side of relay are 8, IIRC.

[red bandit]

Thanks guys. I'll update when I get it done.

[red bandit]

I cleaned the key switch and kill switch, they both looked new. I have full voltage at the plug (out going side) 2" from the solenoid. But I lose 0.2 volts at the red wire just before the plug going to the key switch. Is there any plug/connection in between those two?