Post by highsidednb on Nov 10, 2011 18:44:04 GMT -5
1978 SE, all original wiring (I think) with exception of changes made because of PAMCO.
A few weeks ago the starter button wasn't kicking over the starter and so I tried kicking the bike to life and it worked. What I also noticed was that the headlight wasn't working. The bike got me home from work. Signals worked, tail light worked. Headlamp filaments are intact and it's not blown out.
I took a look at all the visible wiring I could and I thought I found the problem. There are several connectors between the seat and the rear fender. I saw that one of the connectors was loose (a yellow one.) I pushed it together and then the bike started w/pushing the starter and the headlamp worked! Aha!
Well, here we are today and the same thing happened. No headlight, no starter button. I looked at the same cluster of connectors and saw nothing wrong. I checked the fuses. I checked the other visible connectors I could find. All seemed connected and intact. So, no correllation with the above.
Is there some kind of relay that both the headlamp and starter button are on? Am I screwed and doomed to replace the entire wiring harness? Could it be the Kill/Light:On Off/Starter switches? It doesn't seem like it's a current issue as the bike runs and the other lamps work.
The safety relay cuts power to the starter solenoid trigger as soon as it senses alternator output to prevent damage from accidental starter button pushes, and on your E-model it also cuts power to the headlight when the solenoid trigger is closed and restores the headlight when the trigger is open. On your bike the SR is the gadget with two metal domes (under the right side frame cover, IIRC); one dome houses the relay for the starter and the other houses the relay for the headlight. If in doubt consult the wiring diagram in your manual and confirm identification of the part by wire count and color. Clean the connector, and if that doesn't help, come on back and I'll tell you how to bypass.
On the 78 it has a fuse block to hold the fuses. It was ok when new, but after 30+ years it ain't so good. The clips that hold the fuses get weak and don't carry current as well as they should. If your bike still has the stock fuse block that might be the trouble. Replace the fuse block with inline fuse holders. Use fuse holders that use modern blade type fuses, much better than the round glass fuses. Leo
75 XS650B with 79 forks and dual disc, braided lines, disc brake on back, Pamco ignition, Pamcopete's reg/rec mods, kill switch relay, home made harness, all LED turn, brake and tail lights, tapered head bearings, bronze bushes in swing arm, soon to get shock and fork upgrades
Hi Leo I'm a newbie and have same problems posted above. My frame manu is 4/80 but the engine is an '82. I not having luck with searches but have picked up great info on numerous posts. I powered up both relays, got a distinct click and thought they passed the test. I did wrap two bare wires in the headlight basket, one was outside the grommet, go figure. I noticed there is no charging when the headlight is off. The battery is new and I have been keeping it topped off after my rides around the block (highly illegal with the 2004 (Alabama) tag). I like the double pole double throw 20 amp toggle switch idea! The two metal domes have 6 wires coming to the plug. Would you please give your knowledge how to wire this switch or a direction to a post already done? Thanks. Two friends gave up on this bike after ten years and gave it to me, how lucky. The motor went to a shop and was taken out to 10 over on the rings. I thought I was ready for the Gatorade bottle manometer sync but nobody told me it could not only suck the water from left bank but suck the bottle flat too. I guess the left cylinder rings aren't quite seated yet. I've really enjoyed the last 4 weeks working on this bike and researching how to bring it back to life. Cleaning the dirt-dobber's nests and vise-gripping old screws out have been the hardest jobs. Somebody really gorilla-ed them in there.
Last Edit: Sept 1, 2014 19:28:00 GMT -5 by getinhot
r80rt: :)This is a splendid write up, THANK YOU!!!!
Dec 26, 2015 16:54:05 GMT -5
mashermoto: What the what is this shoutbox for? Or should I shout, WHAT THE WHAT IS THIS SHOUTBOX FOR!
May 12, 2016 22:22:21 GMT -5
motormike: Good Day ...just a FYI.. Wild Cat is this Labor Day weekend. Still go'n on. A few 650's still make the scene. Various rides at different skill levels each day.. awards dinner sunday eve. BS in the park'n lot after dinner.
Aug 23, 2016 7:57:01 GMT -5
lsettle: First post in over 6 years!
Aug 28, 2016 19:45:17 GMT -5
kardon: Wow quiet here, where did they all go.
Oct 7, 2016 2:18:13 GMT -5
gggGary: XS650.com LOL
Feb 16, 2017 20:49:02 GMT -5
buell88: Anybody have any idea who built the xs650 tracker used in the Draggin Jeans Ad on Pipeburn?
May 16, 2017 16:24:09 GMT -5
joshua: The regulator/rectifier unit I got from Mikes PMA has closer hole spacing than original. Are we supposed to mill the holes to fit?
Jun 7, 2017 19:25:58 GMT -5
joshua: My bad. I found the bracket they supplied to mount the rectifier/regulator... Uh oh. How is this meant to work? Which way is it meant to mount? Looks like I have to use some spacers or something. Good instructions would be nice.
Jun 7, 2017 22:09:52 GMT -5
craig8johnson: Not sure if this is the right spot or not but oh well...
Jul 11, 2017 18:04:15 GMT -5
craig8johnson: I'm checking the charging system. I'm afraid I might have fried the last battery. With the solid state regulator (after market) what should it be charging at. The book says, I think, 15 volts. I'm hitting 17 when revved. Is that too high?
Jul 11, 2017 18:06:19 GMT -5
gggGary: Yes 17 volts is too high, about 14 volts is max, sounds like you don't have the right regulator or it's wired wrong.
Jul 13, 2017 6:54:33 GMT -5
dean: Just saying Hello, new member who is going to fix up a 79 XS650 that has seen its better days. I will definitely have lots of questions coming up.
Jun 23, 2018 16:45:32 GMT -5
tt650: Trying to breathe life into a 1980 that's been stored (indoors) for 25 yrs. Air filters are dry rotted. Have cleaned carbs but she only runs briefly on choke then stops. Need jet setting info and other ideas that might help her idle and rev.
Jul 3, 2018 19:15:19 GMT -5
trix13: Hey everyone! New to the forum and am fighting those gremlins!! New charging system, ignition switch, coil and fuse box. Resistance is higher than normal on the ignition pick up so I'm trying to find one. No such luck yet.
Aug 16, 2018 8:50:48 GMT -5
trix13: Also, even though all of my connections are clean, I cannot seem to find out why , when at higher rpms, I hit the signals and the rpms pulse with the signals...hahah. same with the brake light. I appreciate all input!!
Aug 16, 2018 8:55:08 GMT -5
bob99: how do I post a question. I am new to the forum
Jun 6, 2019 10:52:10 GMT -5
adlpc: Hello all! Been enjoying your edifying posts and discussions - and as a fan of the XS650 since my early teenage years happy that I now own a 1980 Special which I plan to turn into a vintage half faired racer. Thank you all for being here!
Oct 1, 2019 0:58:56 GMT -5
jimothyj: Hello everyone, I just joined & wish would have known about this site in 2014 when I brought my 1974 TX650A back from the grave. I have spent a good deal of $$ and alot of time on it. Just painted it and working on electrical, I will post pics soon,
Apr 10, 2021 2:14:13 GMT -5
louisvan: trix13 - I had a problem with my 1975 SX650. When I got to highway speeds, the engine lost power. The problem was in the connectors. At a certain vibration and the wind pushing on the wiring loom, the connector lost continuity. A bad crimp to the wire.
May 20, 2021 1:19:09 GMT -5