Electrical, ignition coils, TCI?

Hello all. Riddle me this. Maybe someone has come across this problem and can help. My brother and I have stretched our knowledge bank and the pages of the manual are frayed.

1980 XL650G
Problem started a couple months ago where I would lose all power while riding. It generally happened between mile 2 to 4. It was like I hit the Engine Stop switch. It then wouldn't start unless I turned the Stop switch to off and then back to run. It was then running good for the rest of the day. The problem has now progressed to to stopping more often. ie. 4 times in 10 miles.

What we have done:
• tested wire connections and a visual on the wires (3 times now)
• cleaned up the corrosion in the fuse box, grounds and connections
• replaced the Stop Engine switch- original was very touchy
• rewired the Ignition fuse with a 10A clip in
• placed electrical grease on snap connections

Any help or a manual page would be greatly appreciated. Note: this model doesn't have a kick stand switch. Thanks much.

 

Saw something like this once but my not apply here. A member had a bike with the wiring pretty butchered and when he turned the handlebar he got a short or on some bounces. I know you checked our wiring but could it be an intermittent short?

I had a similar top switch thing where I believed I needed to turn it off then on to get starter to turn. Wound up being my solenoid was going bad.

 

it should have some relays in it, and maybe moving the stop switch works these relays and they make contact for a while
you can pry back the tabs on them and open them up, slide some fine sandpaper (400 or finer) through the contacts, spray it with LPS 1 (no WD40) and put it back together
might help, can't hurt

 

Thanks guys. A couple of good ideas. I hope I can try them out this weekend. All depends upon the war department and her plans.

 

"The war department and her plans" LOVE THAT!!! :lol:

 

I have the exact same problem and a local bike mechanic told me that the xj650`s were natorious for coil, and coil pickup problems. I am replacing mine as we speak.

 

Why does it always work when it's in the shop? Everything is still testing fine, so we started rigging things up to test on the road when then problem occurs. We wired up a light to the snap connector in front of the coils and I carried along a spark tester. We now know the problem is some where between the two. When the power dies... the light still glows and when I push the starter there is no spark.

Got some good information off the "CDI Question" post. Will try the test this weekend.

 

Final update on last year's problem. The problem was the TCI. Finally found one and put it in this evening. Runs great.

Thanks for all those that helped. I'm back on the road.

XJ rules.

 

LOve these forums man.. I was having the sam issue and this hopefully solved my problem..