Topic: Wiring issue on one of my other bikes not turning off and shocking me!

[jamesv220820]

So I was hooking up another bike after a frame off restore (1972 ts185) and kicked it over and started right up , went to turn it off and it wouldn't turn off!

It has a 3 position ignition switch  (off, on, on with lights)

Now on off position everything is off but when the bike is running and I turn it to off she doesn't turn off but everything else will
On position 2 the things that are suppose to be on are on  (neutral, oil light horn)
Position 3 Lights are added to the mix.

Now the very interesting thing is when I was doing testing last night and went to pull the key when the bike was running I got one hell of a shock on my hand when pulling they key. Unfortuanwely I can't just buy a replacement ignition switch cause I can't find one but also I am guessing the issue isn't in the switch itself.

Anyone have this issue? Anywhere I should look for to track this issue down?

Cheers
James

[jgger]

Perhaps a misplaced ground to coil. Check for voltage to the coil with the key in the off position, then work backwards from there. Might be a worn wire making an unintended connection.

But that's just a guess.

[BenelliSEI]

Getting a coil to fire back thru the power lead (I assume that’s how it’s getting back to the key switch is more likely wiring at the coil rather than the switch. Something cracked and shorting or wires crossed over at the coil?

[HondaMan]

It's been since 1974 that I worked on a TS185 from my shop (nice bike, BTW), but IIRC it has a magneto ignition that gets grounded from the dyno's coil at the keyswitch when turned off. There might be a connection missing between the mag's coil and the key. If so, that would explain the shock from the keyswitch (which also happened with the TC/TS90, very similar wiring).

[jamesv220820]

Cool yeah the wiring diagram isn't as cool as hondas so I will have to just go through it all

[HondaMan]

Cool yeah the wiring diagram isn't as cool as hondas so I will have to just go through it all

Hey! Seeing that wiring diagram jogged my [crusty?] memory a bit.
The case of the switch is the ground that is used to short uot the mag when OFF. If the mount is over-painted (like during a resto) it loses the ground contact to the frame. The engine must also have bare surfaces on the side of the frame where it contacts the engine at the mount bolts, and the keyswitch has (or HAD) a bared sopt by its mounting ring (some had screws) to also do this grounding thing. If the bike has poor grounds, it shocks the rider during turn-off and the battery is chronically low.

The latter is true of the SOHC4 bikes, too, if the left top rear engine bolt-hole and frame are not bared to each other (usually after repainting).

[jamesv220820]

Cool yeah the wiring diagram isn't as cool as hondas so I will have to just go through it all

Hey! Seeing that wiring diagram jogged my [crusty?] memory a bit.
The case of the switch is the ground that is used to short uot the mag when OFF. If the mount is over-painted (like during a resto) it loses the ground contact to the frame. The engine must also have bare surfaces on the side of the frame where it contacts the engine at the mount bolts, and the keyswitch has (or HAD) a bared sopt by its mounting ring (some had screws) to also do this grounding thing. If the bike has poor grounds, it shocks the rider during turn-off and the battery is chronically low.

The latter is true of the SOHC4 bikes, too, if the left top rear engine bolt-hole and frame are not bared to each other (usually after repainting).

Good to know, Yeah Everything was powder coated and the only thing I hit with the dremel was the frame where primary ground out of the wiring harness connects to

but yeah here is a picture of the coil holder and ignition switch holder (from the internet)

[jamesv220820]

Here is the bike in its current state, I hate to go around and start sanding off powdercoating

[grcamna2]

Here is the bike in its current state, I hate to go around and start sanding off powdercoating

You can scrape-off the coating underneath where the switch mounts to the frame and put dielectric grease there to keep it from corroding,if you do it carefully no one will see it.That is a nice restored one. 

[Robbo]

You could run a temporary wire from the switch body to a known good ground as a test to see if that solves the issue...prior to scraping off more powdercoat.


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