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Part III - Spark (Yay!) But No Electric Start, No Horn
- Thread starter swagsherman
- Start date
swagsherman
XS650 Enthusiast
Yeppers. Again,
. I'm drinking beer tonight for sure (happy beer, as opposed to my usual "I wonder if Tim really will come get it" beer)!
So, it seems you've experienced firsthand the major drawback to that clutch safety switch and it's associated relay. If something in the system goes wrong (no neutral light in your case) it cuts power flow to the starter solenoid. That's why I eliminated it, lol. But you can't just remove the relay. Power flows through it to the solenoid so you need to add a jumper wire to the relay plug to re-establish that power flow path .....
The horn works like the starter, except the power don't go through no relays.
Power goes to the horn on a brown wire. From the horn on the Pink wire. The pink wire goes up to horn button, button ground to bars.
I would start at horn, unplug the brown wire and check for voltage. If you have voltage plug the brown back to horn. Unplug pink wire Jumper from horn to a good ground. If no toot horn may be bad.
They can be opened up and contacts cleaned. Drill out stock rivets, pop rivet back together
Read about it on here. Done 3 or 4 now. All work fine.
If you get toot then rehook pink wire. Try the button. if no toot may have a bad contact on button or bad wire.
Again open up and clean.
Leo
Power goes to the horn on a brown wire. From the horn on the Pink wire. The pink wire goes up to horn button, button ground to bars.
I would start at horn, unplug the brown wire and check for voltage. If you have voltage plug the brown back to horn. Unplug pink wire Jumper from horn to a good ground. If no toot horn may be bad.
They can be opened up and contacts cleaned. Drill out stock rivets, pop rivet back together
Read about it on here. Done 3 or 4 now. All work fine.
If you get toot then rehook pink wire. Try the button. if no toot may have a bad contact on button or bad wire.
Again open up and clean.
Leo
swagsherman
XS650 Enthusiast
Thanks XSLeo, I'll get on that today after I finish basking in the glow of having repaired *most* of the electrical problems. I only use the horn to talk to the local cows anyhow.... (Insert cow emoji here)
Like the starter the horn button goes to ground on the handlebars. Try grounding pink wire in headlight bucket to check the the button and ground .
swagsherman
XS650 Enthusiast
And, horn fixed. Just had to order a new button. Old one was covered with build up then it broke when we took it out. AND, because she's no longer broken, getting new sneakers fitted tomorrow. All set for spring!
We'll make an electrics guru out of you yet. 
swagsherman
XS650 Enthusiast
Has Mikes responded yet re. their second harness?
swagsherman
XS650 Enthusiast
Yes... Said they were sorry, restated that they've had no issues with the harness, that they'd look into it, and that they're glad my bike is running again. Finally, that they were there for any other parts I might need. I didn't respond.
Their bad harness cost me 2 1/2 weeks, lots of frustration, and $70 (with shipping). I knew there was no way I'd be able to return the second one. Mikes still thought (maybe still does) that the problem was me and/or my bike - said as much when they authorized the return of the first harness. So, we cut into the second one to try to find the problem, then grabbed the fuse box out of it to replace the broken one on the OEM I picked up.
I'm just glad it's running and will likely look elsewhere for parts.
