Intermittent Ignition - Troubleshooting

[Dark Horse]

I haven't had time yet to do the usual trouble shooting for the problem I'm about to describe. I am hopeful that someone recognizes this problem and is able to save me a little time.

The Dark Horse has been running great until the last couple of days. (In advance, Yes, I did the pick-up coil rewire last year.)

I am intermittently loosing ignition on two cylinders. When this happens I can get those cylinders back by holding in the clutch lever and reving the engine; sometimes by changing to a higher or lower gear; or by stopping and letting the engine come back to idle speed.

I won't have an opportunity to work on the bike for a couple more days. Then I will get out the VOM and check circuits, etc. Some of my riding buddies want to go on another day trip early next week. So I need to get the old mare up and running.

Any input from the forum will be greatly appreciated as usual.

[karateman]

im wondering if i have the same problem ........are the cylinders that you are losing running off different coils ? for exsample 3 and 4 or maybe 1 and 2 .................. if so let me know what you come across . and whats the rewire you mention in your story!!

[Mike Hart]

Bob, it sure sounds like pickup coils - have you revisited last years' fix? I think it was Jim M. who said he had a 'fix' go bad and had to redo it?

Could it be the spark plug wires? Fuel hose kinking?

Does it happen when the engine is cold? hot? both?

[Dark Horse]

Intermittent Ignition - Troubleshooting

Karateman,

For more info about the infamous pick-up coil weakness in the XS1100's go to the Forum. Look under the Repairs section, then Battery & Electrical, then the heading: "The Coil Pick-up Fix". Sooner or later they will all need this done.


Mike,

I'll know more when I get time to work on the bike. But I will re-check the pick-up coils. Temperature doesn't seem to be a factor. I don't suspect the spark plug wires since two cylinders shut down exactly at the same time. It does sound more like the pick-up coil problem. I hadn't heard of anyones repair going bad. Specially so soon after they had been fixed.

Thanks for your input guys.

Ride safe!

[Dark Horse]

Karateman,

I also noticed an article "Pick-up coil wire repair" in the same section of the forum. Ken Talbot did an excellent job describing this job and he always has some great pictures to help you get through it. (Thanks again Ken!)

Ride safe!

[Madness]

You are right Mike. It was me that had my pick-up wires break after my repair job. If I remember right, it was a little less than a year since the fix they rebroke. I cut and soldered the wires and used shrink tubing to insulate. It rebroke just inside the shrink tube above the solder joint. I think the stiffness of the shrink tube caused the wire to flex there and it rebroke. I replaced the whole pick-up wire harness with a new one I got from Zanotti's.

[Mike Hart]

Jim, do you have the part# on that harness? Remember how much it cost?

[Madness]

Mike,
Can't find package it came in. I bought it about 2yrs ago. I think I paid Zanotti's around $75. I checked on Bike Bandit site. The part # listed for my LG is: 2H7-81676-10-00. Their price is: $98.87.
Installation wasn't too bad except for one little screw right underneath the bike next to the oilpan for a bracket to hold the wire harness in place.

[skids]

Hey Jim, How muct did Zanotti charge you for the pickup coil wire unit? Was it the harness thing and the coils or did it include the plate?

>>I replaced the whole pick-up wire harness with a new one I got from Zanotti's.
Jim Middlestadt<<

[Madness]

Hey Jim, How muct did Zanotti charge you for the pickup coil wire unit? Was it the harness thing and the coils or did it include the plate?
Skids


Around $75 for the harness. If I remember right it came with the coils, but don't quote me on that. No plate that I remember. Are you talking about the plate with the timing marks?

[Dark Horse]

Mike and Jim,

Hey guys, thanks for your input. I got to work on The Dark Horse yesterday. You were right. I found a broken pick-up coil wire!

Last year I used heat shrink insulation around my soldered joints and it was too stiff. The break was at the edge of the heat shrink.

I re-wired all with wire from VOM test cables (more flexible) and insulated with liquid insulation (soft and flexible). Then I went for a twenty mile test ride. Runs great again.

I hope this fix lasts longer. Again thanks for your help.

[Madness]

Alright Bob!! Glad I was able to help. That is exactly what happened after I did my fix.