Please Help!

I have been ***king with this thing for almost 2 weeks now and cant figure out whats wrong. I have no spark to the coils on this bike. Its a 82 XJ650 (Yics) I have full power to the switch and out of the switch. I have all relays working except the headlight It comes on when the bike is running for some reason. I have switched out 3 different coil setups, 3 different voltage regulators, and 3 different stators. Im at my wits end and dont know what to do! Someone please help me fix this thing. (Oh I even changed wiring harnesses twice) Is there anything left to check? The engine ran fine 2 weeks ago. I have been building this bike from frame up and this is the last obstical to tackle.

 

Unplug the Safety Relay.
Place Bike in Neutral. Bike MUST BE IN NEUTRAL.
See if Bike runs with Safety Relay Unplugged.

Yes. Safety Circuit Fault -OR- NOT a Safety Relay
No. Troubleshoot Ignition Circuit

 

Is the saftey relay right below the voltage regulator?

 

It has to be in neutral or It wont turn over. It will crank all day long but no fire. How do I bypas the saftey relay? jump across the selenoid?

 

Just Un-Plug it.

 

Ric is there a way to bypass all of the "safety" features to help trouble shoot? I mean some creative wiring to cut them out of the loop?

S!

 

Stop panicking & start testing out the components.
Ground the plugs on the head, pull the connector at the igniter, flash 12v to the pair on one coil, the plugs should spark, then do the other pair, OK?
Now connect back up 7 with ignition on run a feeler gauge close to the pick up coil (s) plugs should spark, no spark, test the igniter.
Make sure you have continuity across all grounds.

 

If your headlight comes on when the bike is running then the relay should be fine. These bikes are designed for the headlight to come on only when the engine is running and not when the key is turned to the on position.

 

With the engine cranking over how much voltage should be comming out of the pickup coil wires? I believe its 3 wires comming out of there?

 

No. But, having a NON Safety Relay in where the Safety Relay belongs makes the Bike seem haunted.
The Bike will ONLY Start IN Neutral.

BUT, <--- That'a a BIG But,... The CLUTCH Switch becomes Reversed.
The Starter WON'T Turn with the Clutch Lever PULLED.
The Starter WILL Run with the Clutch Lever RELEASED>
Very Dangerous Situation.

Especially, on-the-road ... where we have learned, By Habit, to Pull the Clutch Lever to start the Bike at a light.
With the Bike IN GEAR ... the Starter >>WILL<< Engage with the Clutch Lever >>Released<<. Setting-up a LURCH Forward situation or even a Start.

If you encounter that situation ... UNPLUG the Relay. Then, the Bike will ONLY Start if it IS IN NEUTRAL.

 

Ok im going to pull that relay and see If I get fire to the coils. If I dont get fire to the coils should I be checking the voltage comming from the picup coils behind the left side engine cover next? If so what Is the voltage that supposed to be comming from those wires 12 volts DC?

 

No.
A low Ohm Magnetic Reluctance Signal.

The Rotor passing over the Pickup Coil sends a Signal to the Brain.
The Speed at which it passes-by the Pickup Coil determines when the Spark Fires and at what advance.

Now, ... YOU NEED A BOOK!

The book will educate you and explain the system. Suddenly, you will understand it and go looking for the fault. With the background of knowing what is happening ... you'll get it!