Topic: 1981 XS650: Lost spark and starter button

[Scott S]

 I'll try to add as much information as possible without making this TLDR.

 Picked up a 1981 XS650 from a friend. Cafe/Tracker style with a simplified wiring harness. He had installed a new battery and we both turned the engine over by the starter button. Tested it again after I got it home.

[Scott S]

 I installed the stock headlight bucket and ran the wiring inside the bucket. I fixed a burnt out bulb in the speedo, and I attached an LED light to the dangling Neutral wire.
 I also installed a new master cylinder and grips, so the RH control came on/off a couple of times.

[Scott S]

 I fully rebuilt the carbs, got them back on and fired it up.
 I noticed the starter button didn't work.....turned out the wire came loose inside.
  After trying unsuccessfully to solder it back on, I ordered a new RH switch. Even with the starter wire loose, the bike started on the 5th kick or so, idled, ran and revved. Then it died.

[Scott S]

It died, and I have been unable to get spark or a working starter button since then.
I have headlight Hi/Lo, a speedo light, a neutral light, a horn and working tail/brake light.

So far, I have:
- cleaned paint on the bars, still no starter from the button.
-changed fuses
-new plugs, plug caps and trimmed back spark plug wires
- checked continuity on starter button.
- I have 12V coming from the wiring harness and LH control.
- when I plug in RH control, I get voltage through the plug.
- when I push starter button, I can see voltage to the BLACK wire through the button.
- when I run a jumper (ground) from the switch side of the RH control (Blue/White) to the engine, the starter turns but I have no spark.
- when I run a jumper (ground) from the Blue/White wire on the main harness, the engine turns by the starter, but no spark.
- I have voltage to the RED/WHITE wire that goes to the coils. The ORANGE wire, from the ignitor box to the coils, shows 0.66V.

Still no starter from the button. Still no spark.
What am I missing? What would cause the starter button to not work from the control? If I am using a jumper/ground from the harness and the starter turns, that means the wiring harness and solenoid are good, right?
What could cause the loss of spark? Bad TCI unit? Like I said, the bike started, ran and revved from the kicker....then died. I haven't been able to get spark since then.

[Scott S]

Video links coming, but I made a jumper to ground and the starter button works now. BUT....still no spark, which leads me to believe the TCI may have failed? Also, I get a spark at the plug(s) when I turn OFF the key, but nothing when cranking the bike. What does that mean?

[Scott S]

I realized as soon as I stopped recording that I would NOT get spark at the plugs because the coils weren't plugged in. They still don't get spark even after plugging them back in.

[Scott S]

 With everything connected, I still get no spark when cranking, but I get a spark when turning the key to OFF. Each plug will spark against the head when I cycle the key from ON to OFF.

[Gurp]

Really sounds like a wiring issue. I would rewire it myself or undo anything you've added to the harness. If it's a simplified harness it won't take but a hour or 2 to redo. And it will save hours of checking through harnesses for might might be a intermittent issue which will be near impossible to find with a test light and multimeter. Unless you are homing out point to point on the harness looking for a abnormal resistance.

Sent from my LE2127 using Tapatalk

[Scott S]

 I ran a dedicated ground from the frame to the RH control. Starter now works from the button.

 No spark though. Checked/cleaned connectors on the TCI box and harness. Checked continuity on harness from box to coils. It's looking like the TCI box crapped out on me.
 There's a "Gonzo" replacement that uses a GN250 CDI. I'll work on getting one of those.

[Gurp]

I just went through this headache on my XS650 chopper that had caught fire in a shop accident. You would really think that for such a cult bike replacement parts would be readily available I wanted to replace my pickup coils but alas had to drill out the rivets and put them over onto the new stator. For ease of dealing if I had to do it again if probably convert to points.
I'll look around I may have a extra TCI box.
No promises though.

Sent from my LE2127 using Tapatalk

[Scott S]

 That would be great. It's the 6 pin model, for '80-81.
 There's a "Gonzo" TCI replacement that the guys on the XS650.com forums came up with. Uses cheap, readily available Suzuki GN250 CDI units. I'll give that a shot, too.

[Gurp]

That looked like a cool swap. I decided against it bc my buddy was putting my XS650 together so he can ride it. Didn't want to throw any extra wiring on him. He can read diagrams but not so great and converting.

[Scott S]

Got the Gonzo CDI replacement hooked up and I have spark! I need to put it back together, neaten up the wiring, add fuel and pull out the timing light...still need to check that the trigger wires are correct. Hopefully, she'll be running again by the weekend!

[Scott S]

[ekpent]

Works so good you don't even need gas to run it !

[Gurp]

Did you make or buy the adapter harness?

[grcamna2]

I like that 'gonzo' set-up for your TCi electronic ignition Scott S.
I imagine the new right-hand switch didn't ground to the bars,then the rubber mounted? bars ground to the frame:it can be a pain.

[Scott S]

Did you make or buy the adapter harness?

 I bought it from a guy on the XS650 forum. Some people make their own, some even use individual crimp on connectors. The guy who made mine made a few for sale after he did mine.

[Scott S]

I like that 'gonzo' set-up for your TCi electronic ignition Scott S.
I imagine the new right-hand switch didn't ground to the bars,then the rubber mounted? bars ground to the frame:it can be a pain.

 Yes, even though I sanded the handle bars, I still had to run a dedicated ground.