Check here; The bottom link on the LH side, "650G/SG Supplement (836k)" has the factory TCI troubleshooting guide, it's about 5 or 6 pages down, as good as any, better than most.
http://www.biker.net/650_service/650service%20main.html
This manual is great! I'm definitely bookmarking it...
According to the troubleshooting chart, my TCI box is bad (weird because I took it off a running bike, but I'll bite). So I took the TCI off my 83, which also was a running bike (7 pin instead of 6, but I saw one of your posts that says they are all plug and play, so I tried it out). Still no spark.
So here's what I'm thinking:
A) both TCI boxes are bad, which I think is unlikely
B) I've got a bad connection somewhere that I missed. Maybe if I check each wire at each connection (well each connection affecting the ignition) for continuity it would solve this?
C) Bad ground? I eliminated the motor mount ground, maybe I should put one there? The motor is grounded through the mounts, but maybe it's not enough?
D) Maybe the damn thing is sparking, but I just can't see it? I'm going to widen the gap on the plugs a little and turn off all the lights in the shop, just in case.
If you got a test light handy go threw the steps
You could use a meter too
You have two wires coming from the TCI to the coil Different colors one is also the same color on the TCI plug RED/WHITE ORANGE you should have voltage there. Check the TCI PLUG should have voltage there too.Also make sure you have the three wire hooked up from the pickup on the ALTENATOR.
The wiring on a stock TCI setup is as follow
3 wires plug that comes from the ALTENATOR TCI Box 6 or 7 pin connector and 2 Wire connector for Coil.
If you have 12 volts to TCI and to Coil with key on you should have spark
Could have BAD COIL - BAD TCI Box- BAD PICKUP on ALTENATOR
Let me know how you make out and here is a stock diagram for 1981
Thanks Rich, I've followed all of these steps. I have battery voltage at the TCI plug and the coil plug. The coil tests within spec for resistance, as does the pickup. So your suggestions also point to the TCI. I've tried the 2 I have with no luck. Maybe the measures I listed above will help.
Thanks guys, please let me know if I'm on the right track, or if there's anything else you think I might be missing. I'm gonna head out to the ship right now to try these things.