Cutting out whilst riding.

Hi Guys,

I couldn't find this via the search and started looking back page by page, but thought it would be better to ask. Thing is.. I don't want to ride my bike, because it's randomly cutting out.

To start - I have a Yamaha XJ650 1980. It is my first bike, please excuse me if I haven't been specific enough with the model - I really don't know a lot about bikes as I have only recently got my license.

The problem. I tried starting the bike at work and it started ok, then cut out - plenty of revs, was just getting warm, though. I thought it was because of the bike being cold - until I pressed the starter button and nothing happened - no click, no anything. At this point - I still have power, my neutral light is still on and my bike does not have a side-stand trip switch (wish it did - been riding twice whilst it's been down.. and you never know until you actually need to damned well turn...)
To start the bike (I don't know why I tried this, I just did) I banged the handlebars to the left - and then the ignition button worked. However, it wouldn't before.
Still treating it as a one off, I left - then at the lights, it cut out again. Same thing - wouldn't start until I banged the handlebars to the left, then it worked.
I kept the revs above 3k all the way home until I hit the backstreets into our place, then had to lower it to ride though - and as I got tot the top of the hill, it cut out again. Same thing - ignition button wouldn't work until I banged the handlebars.

My questions are - why would tbe bike cut out if it was a problem with the ignition switch? Or is it a problem with the emergency cut-off?
What are people's solutions to fixing it? It's my work ride, so I have to use the car until I get it fixed, so I'm pretty keen on getting it fixed and riding again, but what should I start with?

 

Further update. I just went out and had a play with the bike. Here's what I found. If I wiggle the cable that runs into the emergency cut-off while the bike's running - it cuts the bike out. The funny part is - if I wiggle the part that is *under* the light, it cuts the bike out as well. It strikes me as very odd that it would have *two* breakages in the wires.

At the risk of over-explaining myself, I noticed that the wires go from the emergency cut-off into the headlight? Then from the headlight to wherever they go down the bottom. Question is - anyone know if there's any joins, or circuit boards inside of the headlight? Anyone else had a similar problem with short/open circuits relating to turning the handle-bars?

Sorry if I'm sounding like a complete douche, here, but I have absolutely no mechanical experience at all. Did carpentry for years, and I'm a telecommunications tech by trade, so I should understand what i'm looking at in regards to wires... but I have no experience taking bikes/bike parts apart and I'm not sure I would be able to put it all properly back together...

Any suggestions?

 

LIKE i said in your other post, you'll have to get a manual for the bike before you or we can try to explain things.


Cheers, Graham

 

Generally speaking, the connections inside the headlight bucket are "idiot proof" in that the critical ones are in unique connectors that can only be plugged into the correct mate.

It sounds to me like you simply have a loose/bad connection somewhere, probably not an actual broken wire.

It could be in the headlight bucket or at the connections for the ignition switch itself (unless those are in the headlight too.)

Max-X is right. GET A MANUAL so we can all talk intelligently here.

 

Flip-read through the manual last night and found out about the headlight bucket. Had a look at it this morning and cleaned up the contacts. They were pretty dirty, so I used some WD40, then wiped off with a cotton tip. All seems to be good now, banged the handle-bars around and didn't lost connection.
On the downside.. when I was playing around last night, I left the key in the ignition turned on, so I got up to a flat battery and had to get the charger onto it. Anyway, this problem is fixed for now.
Thanks all!

P.S. As posted in the other one where Maxim advised me to get a manual - the PO gave me two manuals (service manual and other manual) to the bike with the bike and I downloaded the owner's manual online.

 

Good progress so far, too bad about the battery. The only advice I can give you on that one is.......
TAKE THE BLOODY KEY OUT NEXT TIME!!!!!!!!
:lol: :lol: :lol:

 

Sounds like a loose ground wire or short, check your wires for craks in the coating or bare spots-like you would with phone wire. Even look for corrosion in the plugs.Then tighten screws and nuts related to wiring harness and the such. Similar thing happened 13yrs ago when i added a tach to a harley sportster, be riding along then just die when making turns. Ground wire loose in headlight harness-hope this helps, use a thin grease on the plugs and such-didnot state weather the bike is stored indoors or out- use the same care in maintaing ur bikes wiring as you would phone or broadband cable. Goodluck hope this helps.

 

To add to hemi haulers advice about tightening stuff up, take a look to see that any rust is removed from the bits that do attach with a screw or nut and bolt. Just because it feels tight and secure doesn't mean it could be corroded where you can't see. Don't know what it's called in OZ, but in Canada the protectant is known as Permatex Dielectric Grease or Loctite Silicone Lubricant, put it on everything to do with the lecky after you have got all the grunge off first.
IE: battery terminals, where blinkers attach to frame, between headlight bucket and ears, etc. you get my drift?


Here's a link to an online OZ parts catalogue, you can probably get it local.
http://www.supercheapauto.com.au/search ... &look.y=18
Continued good luck and enjoy the bike!

 

Quick "shuts off while riding" story:

I had just installed a new battery in my '72 Triumph 500 and it was ever so slightly taller than the original Lucas POS. Not much at all so I thought nothing of it.

Fast-forward to the next weekend. I'm flying down a rural backroad, and blast over a decent bump, and the bike shuts off. OFF, like I'd turned off the key.

Coast to the side of the road, inspect bike. Put stand down, open seat; inspect fresh new electrical connections; everything bright and pretty and tight. Baffled, close seat and figure I'll "try it." Bike fires right up, runs fine.

Hmm. I ride away, mystified but blissful. About 20 minutes later the whole episode repeats itself. Again, the bike runs fine after the roadside fire drill.

Ya know, it wasn't until the FOURTH time that I noticed the two small arc marks on the bottom of the (metal) seat pan where it was shorting out my spiffy new sharp clean ring terminals on the new taller battery, and dropping the whole electrical system to ground (positive ground, British bike) when I went over a stiff enough bump.

A rag was my short-term fix; a double strip of old inner tube my long-term fix; that and filing flats on one side of the ring terminals.

You learn from these types of experiences, as you just have. Welcome to the world of old motorcycles.

 

Nice! I'm having similar issues, bike losing power at turns, throttle bringing it back up, blinkers working intermittently until I wiggle the cable where it goes into the light bucket. I will be getting some of that grease and when I do the fuse box, checking all those wires and connections. You guys are all so informative, hope you know it's appreciated!

 

Very much appreciated!! You doing fuse-box as well? I got a replacement from Supercheap Auto today, going to put it in tomorrow. One thing I do know how to do - wires and fuses. Finally something on the bike I understand xD

And yes.. my bad with the key - that said, I suppose it says something about the neighbourhood that I can leave my bike in a carport just off the road with the key in it - and nobody takes it!!

 

You never know, maybe they tried, but when they found that the battery was dead said "Sod it and went and nicked a pensioners car" :roll:
:twisted: :twisted: :twisted:

 

I hate to confuse the the issue but I had the same problem for almost 2 years! Generally my bike(1980 650 maxim) would shut down while it was warming up for no reason and frequently shut down while riding in the 1st 5 or 10 minutes, I would shut the ignition switch off then on and uasually it would fire right up and I would continue riding. Finally after checking and changing everything I found the problem. I changed the TCI unit and I have never had a problem since!This could be something for you to check out if you can't solve the issue with the wiring.

 

Yeah, fuse box for me next. Steo, let me know how that fuse box you ordered works and how the installation goes. You might experience something that saves me from pulling my hair (what's left of it) out, lol.

 

Problem all fixed with the cutting out, took it for a ride yesterday and rode it pretty hard - no cutting out, or anything. Was just a wiring/contact issue in the back of the headlamp.

I just bought a standard fuse-box from Supercheap auto - not a bike-specific one. Fuses are all the same unless they have diodes installed (very rare) so unless you're a purist and will only put xj parts on an xj bike - save the money and buy any fuse box you can get your hands on. Literally, they all work exactly the same. I'll try and grab some pics later. Only thing I was kicking myself for was not getting the right size shrinking tube, so the terminals are all exposed. I'll grab some during the week and fix it up properly.

 

Sweet, can't wait to see the pics! Should help me as I wade into that foray, lol! Oh, check out the videos I made for the 550.

http://www.youtube.com/watch?v=zXqObFC5vng

http://www.youtube.com/watch?v=mx0zbWXE ... er&list=UL

Peace,