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TCI issues? Gonzo? what to do?
- Thread starter DB90
- Start date
I ran one on my bike for a season. Once the timing's tweaked, you can't tell it from the factory box.
DB90
XS650 Addict
I'm making some pig tails (jumper harness) to plug the Gonzo box into the bike. I'll be putting them up for sale today or tomorrow. Haven't decided on a price yet.... prolly 15-20 bucks each. Makes the box plug-n-play.
A teaser.... 
T6h6o6r
XS650 Enthusiast
Alrighty well I don't think this one's going anywhere soon lol if u do end up wanting it just shoot me a pm I'll send it your way for 80 bux shipping included... And of course I wish u the best of luck trouble shooting your problem!
DB90
XS650 Addict
Awesome!! That may have just convinced me to do the Gonzo thing. Put me down for one!
Maybe @gggGary can move this to the garage and rename it? DB can always start a new wanted ad in the future if need be.
You must be very careful where you mention the Gonzo. It's a trigger.
DB90
XS650 Addict
Haha! How so?
DB90
XS650 Addict
forgot to tighten down the intake boots while installing carbs) cause the engine to damn near redline upon start up?
It happens to the best of us.
ckahleer
XS650 Addict
Are you making the cables long enough to mount the igniter back under the battery box? Maybe you could also make some cables just a few inches long for those that will be mounting the igniter behind the left side cover.
I have ordered a gn250 igniter as a trouble shooting tool. My bike is mis-firing above 4500rpm. I need something to verify if my igniter is bad.
With 12" to work with I can mount mine at the rear of the left cover and at the original location under the battery box.
Sorry, guess you didn't know. They're 12.5" long. Here's the ad.
https://www.xs650.com/threads/tci-gonzo-jumper-harness-pigtail.62269/
https://www.xs650.com/threads/tci-gonzo-jumper-harness-pigtail.62269/
DB90
XS650 Addict
IT LIVES!!!!!!!! Runs like a CHAMP!!!
So my first issue with having no spark was, I'm pretty sure anyways, the fact that I didn't have a good battery to frame ground and my TCI connector was a bit corroded.
The reving to almost redline issue was definitely not a vacuum leak but the new throttle cable I bought is short and had the damn thing open to 3/4 throttle!! Can't believe I missed that part!!!
So my first issue with having no spark was, I'm pretty sure anyways, the fact that I didn't have a good battery to frame ground and my TCI connector was a bit corroded.
The reving to almost redline issue was definitely not a vacuum leak but the new throttle cable I bought is short and had the damn thing open to 3/4 throttle!! Can't believe I missed that part!!!
Inside joke
british standard
XS650 New Member
@DB90, did you manage to sort the no spark issue? I have a client's low mileage and very OE 1980 that ran a treat for weeks whilst in the shop waiting on chrome bits to arrive, and I rode it ≈10mil of a Friday and come the following Monday wouldn't rev beyond 1300ish RPM, loaded or otherwise. I've checked and found the following to be in working order or within spec:
-dynamic compression
-fuel jetting
-checked carb balance
-battery voltage
-disconnected the rectifier and ran it
-ran it off a car battery to insure it has the proper voltage
-measured the voltage directly at the TCI box replaced the coil with a new
-the voltage and grounds directly at the TCI connector (6-pin, btw) & other grounds in system
-magnet in rotor has what appears to be adequate magnetism
-fuel flow through the petcock
-to make certain ran it off a test tank with 93 & 100 octane to remove the possibility of fuel delivery issues
-clean the carb passages & jets
-reset float height & verified needle & seats function properly
-airflow into the airbox
-removed kill switch from ignitor circuit
-new spark plugs, 3 pairs of NGK just to be certain in recommended heat range and a step up and down, just to be certain
-Verified connections from pickup coil to TCI box
-verified connections from TCI to coil
-changed plug leads & caps(getting desperate)
-verified tightness on igniton coil & pickup coil fasteners
-removed pickup coil cover to eliminate potential grounding
I just bought an oscilloscope (which I feel like a chimp trying to land the space shuttle whilst using it) and've yet to hook it up to measure the pickup output whilst running at idle against the TCI output, and also as it increases in RPM. That'll be next unless one of the old timers here has a 'Hey, stupid...' to throw my way. I've been thorough, but am ostensibly human historically prone to err.
I found at least a few other threads on this forum where XS owners have had the 'it ran great [insert single-digit number of day] ago but now only idles' Covid variant, all with bikes running the electronic ignition system, but the threads all seemed to've petered out or went the, now closed, Pamco route. If I had a second known-good TCI box, I'd toss it in. I've ordered one but it has yet to arrive. Any links, insight, advice, or motivating insults are welcome. I'm verging on talking him into converting to points (ignition seppuku) or going with the match, petrol, whoompf! option.
-dynamic compression
-fuel jetting
-checked carb balance
-battery voltage
-disconnected the rectifier and ran it
-ran it off a car battery to insure it has the proper voltage
-measured the voltage directly at the TCI box replaced the coil with a new
-the voltage and grounds directly at the TCI connector (6-pin, btw) & other grounds in system
-magnet in rotor has what appears to be adequate magnetism
-fuel flow through the petcock
-to make certain ran it off a test tank with 93 & 100 octane to remove the possibility of fuel delivery issues
-clean the carb passages & jets
-reset float height & verified needle & seats function properly
-airflow into the airbox
-removed kill switch from ignitor circuit
-new spark plugs, 3 pairs of NGK just to be certain in recommended heat range and a step up and down, just to be certain
-Verified connections from pickup coil to TCI box
-verified connections from TCI to coil
-changed plug leads & caps(getting desperate)
-verified tightness on igniton coil & pickup coil fasteners
-removed pickup coil cover to eliminate potential grounding
I just bought an oscilloscope (which I feel like a chimp trying to land the space shuttle whilst using it) and've yet to hook it up to measure the pickup output whilst running at idle against the TCI output, and also as it increases in RPM. That'll be next unless one of the old timers here has a 'Hey, stupid...' to throw my way. I've been thorough, but am ostensibly human historically prone to err.
I found at least a few other threads on this forum where XS owners have had the 'it ran great [insert single-digit number of day] ago but now only idles' Covid variant, all with bikes running the electronic ignition system, but the threads all seemed to've petered out or went the, now closed, Pamco route. If I had a second known-good TCI box, I'd toss it in. I've ordered one but it has yet to arrive. Any links, insight, advice, or motivating insults are welcome. I'm verging on talking him into converting to points (ignition seppuku) or going with the match, petrol, whoompf! option.
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