TCI upgrade options?

After fighting a bike that would intermittently die, I came to the conclusion that the tci on my bike was defective (I've since torn out apart and found evidence of leaking caps). I bought a cheap used one on eBay and that did solve the bike dieing, but it looks like this tci isn't properly advancing the ignition, since it won't rev above 5k.

So, I'm sure I could find a used tci that works properly, but I really want something that doesn't have 35 year old components.

I did find the following thread:
http://www.xjbikes.com/forums/threads/aftermarket-ignition.45931/

The best option by far seems to be the hyperpak, but they don't have an option for my 81 650 (verified by email). None of the other options in that thread look appealing. That's mostly from a lack of info, and the ability of them to work properly with XJs.

So, what do you do for a tci? What do you suggest I do? Do you have any other threads with useful info? Thanks in advance guys!

 

If you have an actual electronics or TV repair shop in your town they can repair your TCI. If all that is wrong is bad caps (most likely) you can replace them yourself http://www.xs11.com/forum/showthread.php?t=38224&highlight=tci+repair
http://www.jetav8r.com/Vision/IgnitionFAQ.html


Another alternative is to fit a new aftermarket TCI for the '82-on 650. It should run OK, but you may need to swap in cams from a YICS engine for the engine to match up with the ignition advance on the TCI.

 

Well, I had a bit of a caveman approach to removing the circuit board from the enclosure, so the original tci needs more than caps now...

I didn't think about the cams being different, throwing timing off. Blah...

 

there is a company in the uk costs about 400$

also this link on repair
http://www.xjcd.org/General_Electrical

 

Ignitech like I said in that thread, heaps of guys running them here on all sorts of bikes, reminds me I should really order one

 

Typically its the diodes in there that corrode and fail. Caps are also possible
http://www.xjbikes.com/forums/threads/old-yamaha-diodes.32519/#post-391220
They can be replaced easily. If you still have your old one give it a try, what do you have to loose?
The pics in the thread are from my Venture but I have also done it on an XJ11 and XJ750.

 

That's the kinda I was hoping to hear. Just sent them an email to verify that the Sparker TCI will work with an 81. Otherwise there is the TCIP4. With that I would need to program the spark advance manually, and it looks like I need a tps or map sensor. I would like to get away with not having those as it would make tuning simpler.

Looking at the Haynes manual, a newer ignition unit should work for my bike. The only difference is at idle. My 650H is at 10° and the newer models are at 7°. I guess I'm not sure if that's too big of a difference or not. At full advance, Yamaha has a tolerance of 4°, so I think I would be ok. First I need to hear back from Ignitech, and then go from there.

 

Coils could also be cracked or breaking down from engine heat

 

Although I won't rule that it completely, my issue changed completely by switching out the TCI. That has me believing it's not a coil problem.

Also, Ignitech does have a new tci that will work with an 81 XJ650. So I'm slowly working towards ordering one of them. It appears the work day for the Czech Republic perfectly lines up with my counting sheep time, so we are communicating at the rate of one email/day.

 

Search and ye shall find.

Options compiled in an easy to read thread:

http://www.xjbikes.com/forums/threads/aftermarket-ignition.45931/

 

Oh hai JPaganel. That is a great thread! So great, I linked to it at the beginning of the thread

I created this thread to see if anyone had found new option in the two years since that thread had been created. Looks like people aren't actively trying to corner the market on ignition modules for 35 year old bikes

 

Well, the unit I'm running in the 550 is working quite well.

 

Ordered an Ignitech TCI, it showed up yesterday, and the bike ran flawlessly for a short midnight ride last night and again to and from work today! I think my randomly dieing problems are behind me (furiously knocks on wood...)

 

Did they program a stock ignition curve into it before delivery?

 

They don't come programed. You will have to set it up yourself.
I have one in a 1200 Venture and it works great. It did take some time to get the ignition curve set right. Using the included software it is not hard to do.

 

http://www.xjbikes.com/forums/threads/aftermarket-ignition.45931/

I know, I know. I'm being an ass. But this is explicitly covered in that thread.

No. IgniTech has two versions, the programmable and the sealed. Sealed one comes set with stock ignition curve, nothing to program, and no way to do it.

 

As JPaganel already covered, the one I purchased came preprogrammed, and with the correct electrical connectors and pinout. I just plugged it in, set it in my electronics tray under the seat (there's no mounting tabs) and bam! Running bike! Put 46 more miles on it today without issue. Huzzah!

 

And here's some pics of the size of the unit:

https://imgur.com/a/bkjzK

 

You'd think it would have shrunk down a bit over 30 odd years. I'm sure it's still fine, but would it fit in the stock location?

 

I'm very interested , my bike has been showing the same symptoms, I went through the carburators , this may be what I need

 

TheCrazyGnat, one of the biggest size constraints of the original is the heat sink for the transistors, plus this is a generic unit, while the original was designed to work with one bike. Considering those two points I'm glad it's basically the same size as the original. The two differences are the lack of mounting tabs (that can be fabricobbled) and the external connectors

Alan, I'd check out my previous thread since there's a lot of good info in there:

http://www.xjbikes.com/forums/threads/xj650-that-runs-great-until-it-suddenly-dies.75468/

In particular, you want to make sure the gas cap is venting properly, the valves are properly shimmed, and everything for the ignition system has the correct resistance. Good luck!

 

My bike was running great to start the season , then while going to work it began hesitating, stuttering above 6000 rpm, even after switching fuel valve to prime, on the return home it ran well up to about 5- 6000 rpm but not above. So I then thoroughly cleaned the carbs,checked valve clearances , changing a couple shims etc,
Then reassembled and it started and idled better than ever, the next ride to work it ran well until just before arriving at work, about 20 minute ride

 

So now I'm quite sure it is the igniter or tci box , since I also changed plugs, trimmed back the wires and verified spark on all 4 plugs, now to find one hopefully locally to try( a known good one).
Alan

 

Have you tried to rev it in neutral? With the second tci, it ran badly for 1k to 1.5k rpm range and then it ran great again above that. But I could only get to that in neutral.

I'd check the pick up coils too to make sure they aren't failing.

 

See if someone can swap yours into their running machine. I'd offer, but postage might be a bit high.