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Bushyboy's build thread

Discussion in 'The Garage' started by Bushyeyed1, Nov 25, 2018.

  1. 5twins

    5twins XS650 Guru Top Contributor

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    There's a bit of an issue with the two large wiring looms that run down each side of the frame and up into the headlight. Due to their size and weight, they slowly sag down and pull themselves out of the headlight bucket. Yamaha was kind enough to put a couple small holes in the gusset plate behind the steering neck and you can use those to feed some cable ties through and create a cable harness "sling". Stick one through from each side so you end up with a male and female end on each side. Join them together around the harness and snug them up enough to support the two harness runs from sagging .....

    [​IMG]

    [​IMG]

    The above pics are from my early, first rendition "mod". Within a few years, the sharp edged holes in the frame gusset plate cut through the cable ties. I now install rubber grommets in the holes first, cable tie cutting problem solved.
     
  2. Superjet

    Superjet XS650 Junkie XS650.com Supporter

    What kind of coil you running there Bush?
     
  3. 5twins

    5twins XS650 Guru Top Contributor

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    I'm pretty sure that's the 2.8 ohm Andrews Harley coil .....

    [​IMG]

    It's nice that we're able to use Harley coils. That gives us a good selection of reasonably priced offerings.
     
    Superjet likes this.
  4. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    @Superjet like 5twins stated I am using the 2.8 ohm andrews coil. Got the low down from a few of his posts and he highly recommended them.
     
    Superjet likes this.
  5. Superjet

    Superjet XS650 Junkie XS650.com Supporter

    Thanks guys!! :thumbsup:
     
    Jim likes this.
  6. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    I swear I am so close to being done, but its one step forward two steps back lately. I hope the banjo bolts I ordered comes in tomorrow so I can at least put the fuel tank back on and fire it up. Last thing to get it on the road is fabricating a mount for the rear led turn signals where I want them. Everything else after that will be minor details and maintenance. For days a warm front has come in and everyone in this part of North Carolina is riding their bike and yes I am jealous. The cool air is already blowing so time to put back on the jacket, but I promise this baby is gonna be road ready by spring. Pictures to come of course after that.
     
    Superjet, Jim and GLJ like this.
  7. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    So what if it gets 14.6 volts rev'd to 2300 rpm but drains voltage at idle.
     
  8. 5twins

    5twins XS650 Guru Top Contributor

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    That could be normal. There's very little, if any, charging output at idle. Charging output is RPM based. Mine drops down to the mid or low 11's on my voltmeter at idle with all the lights on.
     
    Bushyeyed1 likes this.
  9. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    At least I have the bike look finished. Didn't make it 5 miles down the road and bike cut out again. Calling on the experts again on this one. One thing I noticed if I rev high I was able to make it home. New coil, wires, plugs, battery, brushes already installed. Did the slap test with my feeler gauge and it barely moves when ignition was turned on hardly slapping the case. Should I get mikes xs cdi kit (https://www.mikesxs.net/yamaha-xs650-basic-standard-ignition-kit-xscharge-pma-package.html#) minus the coil and associated parts? Hugh's has one too, but it's twice the cost. Or could it be my CDI unit going out?
     

    Attached Files:

    Last edited: Feb 10, 2019
  10. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    So I feel like I can troubleshoot my charging/ignition issues and possibly fix it relatively cheap. On the other hand it could need multiple parts and repairs or something else break later on with my luck. So I'm at a crossroads on upgrading to a new pma and ignition system? If I do go pma then shod I use points or cdi? What are your thoughts?
     
    Last edited: Feb 11, 2019
  11. Superjet

    Superjet XS650 Junkie XS650.com Supporter

    Nice bike Bushy! you should be checking out the charging troubleshooting guide could be something simple. You should check out DIY regulator / rectifier a bunch of guys and building them and running them me included. Mailman has just recently wired it up on his XS2.

    http://xs650temp.proboards.com/thread/3461.
     
    Jim likes this.
  12. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    @Superjet I have been troubleshooting the issue both with forum info and the manual. I don't think it is the rectifier I am having trouble with, but I believe it is either the rotor or stator ignition coil at this point. Rotor did read 4.9 ohms on my multimeter and if I subtract my leads it's even lower. Did the slap test as well even though battery was low and it's at least energized. I read all the wires in the system and that is what lead me to change the ignition coil last time. I can buy a new rotor for $80 and see if that fixes the problem, but that's only a third of the price I can do a pma setup.
     
  13. Superjet

    Superjet XS650 Junkie XS650.com Supporter

    I purchased a new rotor and died within 100kms. Find a good used one and did someone mention to you about the magnet on the rotor? If weak, it will break up the bike idle and revs. Check out poor magnet on rotor and could be your source of problem. Search for the PMA fails too while you are at it. There have been plenty of problems with those too.
     
  14. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    Yep read about the magnet trick too, but like I said I found a new rotor for $80 so rather just throw that in if needed. I'm going to start from ground zero again today as if I hadn't checked anything. I will look into pma fails too. I guess my thinking with pma is that I no longer will have to rely on the battery.
     
  15. Superjet

    Superjet XS650 Junkie XS650.com Supporter

    If you go PMA since you are running stock crank e-ignition you will need to add another source of ignition to cam activated $$$ (Boyer or Pamco from Pete) These will require a constant source of power and would be wise to have a battery, small one at least.
     
    Bushyeyed1 likes this.
  16. 5twins

    5twins XS650 Guru Top Contributor

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    If you're getting 14.6v charging output when revved, it appears your stator and rotor are working, reg and rec too. When you said you're draining voltage at idle, just how low was it reading? As I mentioned above, down into the low 11's can be normal on some of these with all the lights on. If it gets too low that could mess with ignition operation.

    If you better describe the manner in which the bike died, that may help us trouble shoot the issue better. Did the bike cut out at speed while driving down the road or when you came to a stop at idle? Was it a quick cut out like you turned the key off or did it slowly bog down and die? Was there any breaking up and stumbling first?
     
  17. Bushyeyed1

    Bushyeyed1 XS650 Addict XS650.com Supporter

    So the voltage at idle was draining the battery and got down around 5 volts before I cut it off. Even after the ride it never fully charges my battery like it used to. So it is always around 11.5 volts when I turn it on and isn't enough for the starter to engage more then once. So my issue occurs once the bike warms up usually a mile or two down the road. It made it 5 miles the other day, but it was around 30 degrees F. I will be in at least 4th gear and around 3500-4000 rpm. It stumbles then dies as if there is no ignition; regardless if I pull in clutch, down shift to neutral, rev the throttle, or say fuck a hundred times. It then is very hard to start seems almost like I have to charge it kick starting it a hundred times. I peeked in the cylinder and some residual gas that didn't burn of course since the ignition source cut out. I checked my top dead center was line up correctly as well while I was at it. Today when I go home I plan on starting back over from scratch. I think there was one resistance check that said replace stator but can't remember. Also yesterday the resistance for the rotor was lower then the 5 ohm range it requires. I am also going to get a better look at the wire bundle by the sprocket and make sure its not chaffing or grounding. The issue isn't intermittent it happens under the same conditions; warm, over 4th gear and around 3500-4000 rpm.
     
    Last edited: Feb 11, 2019
  18. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    Color me impressed that the TCI still worked down at 5V... :yikes:
    It's an even bet that your Iggy system is fine. Concentrate on one thing at a time. First thing you absolutely gotta do is get your charging sorted. New battery? Cleaned all connections and grounds? On board voltmeter? If you don't you really need to install one. You said rotor was 4.9 ohms. That's within spec. You also said it put out over 14V revved. That's good. Sounds like either a bad battery or bad connection to (or ground from) the battery.
     
  19. 5twins

    5twins XS650 Guru Top Contributor

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    Are you sure your battery is good? Sounds like even though a charge is being put into it, it's not taking it or holding it. Yes, the ignition probably would quit if the battery voltage got as low as 5 or 6 volts, at lower RPMs anyway. High RPMs with a high charging output would probably keep it running, running off the alternator output.
     
  20. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    Start filling in your "signature." Stuff like carbs.... Iggy used.... type of reg/rec..... all the stuff we need to help you at a glance.
     

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