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Stalls when I put it in gear.

Discussion in 'The Garage' started by Hardfahrer, Jul 11, 2011.

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  1. Hardfahrer

    Hardfahrer XS650 Enthusiast

    I have an XS 650, 82, that I just rebuilt and put back together. When I put it in first gear, the engine stalls. I rev it up, put it i first, engine stalls. Seems that the electrics aren't in order and the engines electrical power is being shut off as soon as it goes into gear. Any thoughts?
     
  2. The TCI (ignition module) is interlocked with neutral switch and sidestand switch. Engine runs in neutral, but when you select first gear you are losing the sidestand interlock. The sidestand switch must be closed.

    Have a look at the switch.................repair it or jumper the contacts.
     
    johnnmcguire and peanut like this.
  3. maxwell

    maxwell XS650 Addict

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    does it drag to a stop? if so, you may just need to adjust your clutch cable..
     
  4. Yep, there's a connector on the left side that goes down to the sidestand switch. I pulled mine apart there and jumpered the wire together....removing the switch altogether.
     
  5. Hardfahrer

    Hardfahrer XS650 Enthusiast

    Thanks a bunch guys. Had my first ride today. I jumped the sidestand switch and that did the trick.
    Many thanks!
     
  6. Ksboy19

    Ksboy19 XS650 Addict

    wheres the sideswitch relay at?? I am using the tcbros simple harness and I dont believe I even have that relay and im having the same problem.
     
  7. Hntg4evr

    Hntg4evr XS650 Enthusiast

    I have an 83 and am having the same problem. I just put a new clutch in it so idk what else it could be. It is jumping in gear and stalling as soon as i put it in 1st gear. The clutch cable is adjusted properly so is this relay the only other thing it could be? Where is the relay located? Can someone post a pic? Thanks in advance.
     
  8. Sidestand relay is on the left side as previously stated by nj1639. It has 4 wires. Red/white, Blue/yellow, Black and Black/white.
    You need to have a Haynes manual......................it shows the wiring for this interlock. Try unplugging the relay.
     
  9. littlebill31

    littlebill31 Smells of Raw Fuel

    My '82 had the side stand switch removed by the PO. In order to make it work I had to tie together the L/Y and B (Blue/yellow and Black) wires to bypass the safety relay. Left side towards the rear fender in memory serves.
     
  10. Hntg4evr

    Hntg4evr XS650 Enthusiast

    Thanks guys, I will try that. If that doesn't work, is there anything else it could be?
     
  11. littlebill31

    littlebill31 Smells of Raw Fuel

    The switch is on the kickstand mount under the bike. The relay is back left.
    Usually it's the switch because people remove it and don't tie in the wires at the relay. Then you get a $250 deal on Craigslist because the bike doesn't run, lol.
     
    Hntg4evr likes this.
  12. Hntg4evr

    Hntg4evr XS650 Enthusiast

    Thanks littlebill, will try it first thing in the morning. That's exactly what this bike was, except it was a $250 Facebook find. Guy said it needed a clutch. Come to find out it was the cable. He just didn't adjust the cable after he put it on. Because it sat for 5 years, I obviously had to replace the clutch plates.
     
  13. Hntg4evr

    Hntg4evr XS650 Enthusiast

    Well just tried the relay, still jumps into gear and stalls. Now I can't seem to get it out of first. Any suggestions???
     
  14. 5twins

    5twins XS650 Guru

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    If you're saying the bike lurches forward when you put it in gear and that's what stalls the motor, then you still have a clutch problem. Your clutch isn't releasing or disengaging. It could be an adjustment issue but it could also be an assembly error from when you put all the new clutch parts in.
     
  15. Hntg4evr

    Hntg4evr XS650 Enthusiast

    5twins, I alternated friction and steel plates. I also aligned the dot in the clutch plate with the one on the basket and tightened to 7ft lbs. Is there something else I should have done?
     
  16. Have a read of the Clutch sub-section in the Tech section. These clutches have been apart many times by POs. Sometimes they add or leave out parts or assemble in the wrong order. I had one spacer washer left out of my clutch by a PO.
     
  17. littlebill31

    littlebill31 Smells of Raw Fuel

    I guess I missed the "jumping" part.

    I am carbon had an extra plate in this video..

     
  18. 5twins

    5twins XS650 Guru

    13,276
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    163
    The guy who sold it to you said it needed a clutch. Maybe he was in there messing with things and that's why it doesn't work right. There's a series of spacer washers that must be in place and in the right places so the clutch hubs don't rub on one another or the engine casings. They also space things properly so the clutch spreads open enough and then engages tightly after that. Maybe that guy messed up the spacer washer sequence. Here's a diagram. There should be two washers behind the clutch and two washers along with a flat radial bearing between the inner and outer clutch hubs. They must be in the order shown .....

    [​IMG]
     
  19. Hntg4evr

    Hntg4evr XS650 Enthusiast

    Thanks 5twins. I checked my worm drive and the 5/16" ball bearing is missing too.
     
  20. 5twins

    5twins XS650 Guru

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    You said you adjusted the clutch cable but did you adjust the worm screw too? You might be able to compensate for that missing ball with the worm adjuster screw but it's best to get a replacement. Even though these are metric bikes, that ball was 5/16" for some reason. A well stocked hardware store may have one.
     

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