Post by tomterrific on Jan 30, 2007 9:11:57 GMT -5
Everyone should be aware that kill switches on old motorcycles are a huge cause of breakdowns. I brokedown twice last year, once on my old XS which I am sorting and once on the old Triumph which is my long time rider. In both cases the kill switch was responsible. The Yam's switch was totally buggered and the Bonnie's harness pin connector had burned. In the case of the Bonnie I was coming back from Mid-Ohio and the bike died. I found a piece of wire beside the road and jumped the ignition, battery to coil. I returned home and rode the bike like that for a while until I fixed the harness. I put a little jumper in the kill switch in the Yam and rode it around until this winter when I decided to creak open the purse and $45 later I have a new hadle bar switch control from Mike's.
The following little mod will prepare you for a failure of the kill switch and get you home. It also works if you blow the fuse on single fuse bikes.
1. Connected an inline fuse holder between the ignition coil and the battery. Locate the fuse holder underneath the seat. 2. Put a blown fuse in the holder. (To keep the contacts from touching) 3. When the kill switch fails, or the main fuse blows, lift the seat, put a good fuse (10 A) in the holder and ride on home. 4. Do not operate the kill switch with a blown fuse as that will "back feed" the short and blow this fuse as well.
Last Edit: Feb 4, 2007 15:18:25 GMT -5 by pamcopete
Post by tomterrific on Jan 30, 2007 16:26:52 GMT -5
I just string a wire in there when it happens. It'll never happen again, right? ;^) Actually what I do is keep a jumper wire with alligators in my tool kit. I can use that wire to jump around lots of bad electrics.
I should fuse the jumper I guess, or a small resetable circuit breaker would be ideal.
I eliminated my kill switch due to numberous bad experienes on other bikes, especially my Harley. On long trips I often ride with a trottle control to relieve wrist fatigue and often found myself inadvertantly shutting off the kill switch when moving my hands to a different position on the bars. Coast for awile until you realize what you did, and then, KABOOM when you turn it back on. Backfires at 90 mph are not nice. If the trottle sticks, pull in the clutch. Sometimes I think motorcycle riders would be far better off if they learned to ride on the older bikes that did not have all the gizmos and rather ride by relying on their skill and witts. That was just my $0.02 worth.
slide I also try to be prepared to grab the clutch for any bad engine problem, even if it means overreving the engine with a stuck throttle. I still like to have the kill switch available so I can then shut the engine off if it hasn't self destructed yet, but in any case, you may want to retain the kill switch for insurance reasons and it case someone else rides your bike, or if you sell it. My little fuse / jumper mod also takes care of an open key switch or even a lost key (I used it once for that) . I keep the seat key in my wallet.
Last Edit: Jan 31, 2007 11:47:44 GMT -5 by pamcopete
I just lube throttle cable to prevent sticking. ;D Did have one freeze open once several years ago. Was an old bike that didn't have a kill switch (around December 1975) I'm still here so it couldnt have been serious ;D PJ
There are three types of people in the world, those who can count and those who can't I dabble in rocket science, when I'm not picking my nose
To eliminate the drop across the "Kill" switch and the "Key" switch, I installed a relay that provides a direct connection to the battery for the ignition coils. The relay is available at most auto supply stores and is normally used to power up auxiliary lights. It is rated at 30 Amps. Mounts on the mounting bolt of one of the coils.
Last Edit: Apr 11, 2007 19:34:53 GMT -5 by pamcopete
Here is a pic of the one that I use. These are generic relays made by a number of manufactures and usually displayed in the fuse and light bulb section of most auto parts stores. They are about the size of an ice cube and come with a mounting tab. They sell for about $5. You can also go to www.wiringproducts.com and look for their part # R-40AT for $5.95 plus shipping. This is a 40 Amp version of the same relay. The advantage of these relays is that the contacts are made from a semi precious metal that lasts longer and is more resistant to pitting. It's like getting a brand new ignition switch for $5.
Last Edit: Mar 2, 2008 15:17:45 GMT -5 by pamcopete
spock Well, the ignition switch from Mikes is $28 and he doesn't list one for pre "late" '78 models. The bar switch with the kill switch goes for $46. (Free shipping! ) The problem has nothing to do with the battery. , but if you insist, an AGM battery costs $59. You should still clean the contacts on both switches if you are not going to replace them. I like the $5 ;D relay idea which bypasses both switches to the coils.
Last Edit: Apr 2, 2007 16:47:53 GMT -5 by pamcopete
Post by mizadventure on Apr 4, 2007 17:33:59 GMT -5
just wanted to chime in on the usefulness of pamcopete relay/inline fuse mod. w/ his kind assistance, I wired in the relay to deal w/ the voltage drop I was getting across my main switch & I'm darn happy w/ the result. no problems firing up and nice having the peace of mind that if I blow the main fuse (as if that would ever happen, right?) I can still get the b
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.
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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.
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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
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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!
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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