glennpd
4 bikes, 4 dogs, 1 wife
I bought a 1980 XS a few years ago as a project bike. Within 1 week it was running like a scared deer. My only problem was that it would drain the battery. After doing only a very little research on the web I found that the XS650 was notorious for shorted rotors.
I then started to investigate and I found the stator connector somewhat toasted and various slices and dices in the wiring. I figured that I need to start with a clean slate and more knowledge. I purchased the CD's on the XS650 electrical. These I found very informative. I was now equipped with knowledge.
I then bought a new loom from MikesXS. It closely mathed the original but not quite the same. I contacted MikesXS and they sent me a replacement which looked better. I removed all the old wiring and installed the new wiring.
I then tested the rotor and found it to be bad (1.2 OHM) and promptly took it to my local Electric motor repair shop for rewind. I also checked the stator (many steps including light bulbs and various chants) and found it to be healthy. OK!
I moved on to the voltage regulator an it too was in good shape. I re traced all the wiring based on the corrected wiring diagram provided with the CD's. and found a mis-connected wire in the headlight. No biggie, I re-connected and re-tested the connections in the headlight and all was as per Mr. Yamaha intended it.
The electrical shop apparently were on a different planet than me because it took them 1 month to get the rotor finished. You know time space kinda thing E-MC2 stuff. Finally they presented me with a finished rotor with 5 OHM resistance. Presently I scurried home and prepared to install it on the crankshaft but before that I thought I would just check their work. Mmmm infinity seems like a little too much resistance. I inspected the
rotor to find that in the process of handing it to me one of the "cold" solder joints globbed on to one of the leads lost it delicate bond.
I grabbed my injured rotor and dashed back to the shop and presented them with the apparent cold solder joint. They promptly handed it back to the man behind the curtain and was informed the OZ fixes all. Lo and behold when OZ completed magic it was healed and ready to spin wildly on the end of my crankshaft.
When I arrived back home I installed the rotor securely on the crank. Re-installed the stator. Connected the stator connector and the tci connector and the yellow reserve lighting wire. The excitement was nearly more than I could bear. Prfime, ignition on, press starter button, SCREECH, GRIND,GROAN! I once again removed the stator to find that the screws from the brushes chewed deep gouges into the copper slip rings but only on half of the rotor. Mmmm could it be that the rotor was assembled tilted? Indeed it was!
Once again pull the rotor find the nearest worm hole to get to the motor shop and presented them with their newest fiasco. OZ handled this one personally and they dissasembled the rotor and re-pressed it together just about perpendicular to the axis of the shaft. Warped my car back home and began to re-surface the slip rings with a block and fine emory. When I thought it was good enough to pass current to the brushes, I re-assembled what now has be come a hobby, rotor, stator, wiring yahta yahta yahta.
Key on, press the button, crank crank crank. Pulled a spark plug, grounded the plug on the head. Crank crank crank, spark, spark spark. Ok maybe the other side. Crank, crank crank, spark spark spark. Mmmm. Place finger of now open spark plug hole, crank crank, crank, Poof, poof, poof. good compression Plugs back in. Maybe more enrichment. Pull the knob all the way out, prime the carbs again. Crank, crank,crank, pop. Less enrichment, push the knob in all the way. You know the drill. Same thing. Maybe ether. pull the air cleaners, spray ether, quickly push them over the carburetors. Nothing Nada, zero zilch.
At this point I started to drink heavily. I will finish this post tomorrow but I will leave out puking, falling down and hangover parts.
Glenn
I then started to investigate and I found the stator connector somewhat toasted and various slices and dices in the wiring. I figured that I need to start with a clean slate and more knowledge. I purchased the CD's on the XS650 electrical. These I found very informative. I was now equipped with knowledge.
I then bought a new loom from MikesXS. It closely mathed the original but not quite the same. I contacted MikesXS and they sent me a replacement which looked better. I removed all the old wiring and installed the new wiring.
I then tested the rotor and found it to be bad (1.2 OHM) and promptly took it to my local Electric motor repair shop for rewind. I also checked the stator (many steps including light bulbs and various chants) and found it to be healthy. OK!
I moved on to the voltage regulator an it too was in good shape. I re traced all the wiring based on the corrected wiring diagram provided with the CD's. and found a mis-connected wire in the headlight. No biggie, I re-connected and re-tested the connections in the headlight and all was as per Mr. Yamaha intended it.
The electrical shop apparently were on a different planet than me because it took them 1 month to get the rotor finished. You know time space kinda thing E-MC2 stuff. Finally they presented me with a finished rotor with 5 OHM resistance. Presently I scurried home and prepared to install it on the crankshaft but before that I thought I would just check their work. Mmmm infinity seems like a little too much resistance. I inspected the
rotor to find that in the process of handing it to me one of the "cold" solder joints globbed on to one of the leads lost it delicate bond.
I grabbed my injured rotor and dashed back to the shop and presented them with the apparent cold solder joint. They promptly handed it back to the man behind the curtain and was informed the OZ fixes all. Lo and behold when OZ completed magic it was healed and ready to spin wildly on the end of my crankshaft.
When I arrived back home I installed the rotor securely on the crank. Re-installed the stator. Connected the stator connector and the tci connector and the yellow reserve lighting wire. The excitement was nearly more than I could bear. Prfime, ignition on, press starter button, SCREECH, GRIND,GROAN! I once again removed the stator to find that the screws from the brushes chewed deep gouges into the copper slip rings but only on half of the rotor. Mmmm could it be that the rotor was assembled tilted? Indeed it was!
Once again pull the rotor find the nearest worm hole to get to the motor shop and presented them with their newest fiasco. OZ handled this one personally and they dissasembled the rotor and re-pressed it together just about perpendicular to the axis of the shaft. Warped my car back home and began to re-surface the slip rings with a block and fine emory. When I thought it was good enough to pass current to the brushes, I re-assembled what now has be come a hobby, rotor, stator, wiring yahta yahta yahta.
Key on, press the button, crank crank crank. Pulled a spark plug, grounded the plug on the head. Crank crank crank, spark, spark spark. Ok maybe the other side. Crank, crank crank, spark spark spark. Mmmm. Place finger of now open spark plug hole, crank crank, crank, Poof, poof, poof. good compression Plugs back in. Maybe more enrichment. Pull the knob all the way out, prime the carbs again. Crank, crank,crank, pop. Less enrichment, push the knob in all the way. You know the drill. Same thing. Maybe ether. pull the air cleaners, spray ether, quickly push them over the carburetors. Nothing Nada, zero zilch.
At this point I started to drink heavily. I will finish this post tomorrow but I will leave out puking, falling down and hangover parts.
Glenn
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