Is it the TCI?

[Venturous Randy]

Took my first ride Saturday and the bike started shutting off. Got caught at a light and it quit and had to do the tip toe walk to get it out of traffic. Got it started and as long as I kept it revved up, I could keep it running. Sunday, I took the battery tray out and cleaned the connections on the TCI and tightened the terminals. I also took the kill switch off and cleaned with contact cleaner. I also put my new diaphragms in and a new set of plugs. It still was acting up.

When I got home today I took a good look at the electrical schematic. I pulled the windshield and headlight and found the emergency cut off switch, the 60º tilt switch, out of the rubber holder and hanging down. I took it apart and checked it inside and tightened the terminals and reinstalled it with a spacer to hold it tight. I started the bike and it sounded very good, very crisp and responsive.

I put it back together and as I started down the driveway, it went dead. I got it started and made a loop around the block and at about 30mph in 3rd gear I let off the gas. The tach dropped to Zero and it was dead. I flipped the kill switch on and off and it backfired and it was running again. I got it back home and again took the kill switch off and checked it out. When checking voltage across the two wires, there is no voltage drop across the two wires.

I really thought I had found the problem with the tilt switch hanging down, but obviously that was not the problem. I don't know anything about the TCI and when it is running, it runs very good, especially with the new diaphragms. I also pulled the pressure sensor hose loose and put a vacuum pump on it and it would rev up when vacuum was applied. I also blew cleaner through the #2 carb tube and it was open. I also checked the clutch lever and it is out all the way.

Tomorrow I intend to start the check on the TCI, but for anyone that knows about these things, is it common for it to be intermittent and run so good when it is running? It is obvious I am loosing electrical power somewhere, but with it being intermittent, I am having a problem isolating the problem.

I appreciate any suggestions.

RandyA

[GeorgeS]

On the older bikes, the generaly accepted TCI maintenance, is to Remove, open box, dry in oven at 110 Deg. F, to remove moisture.

 

then, Follow each wire from the Two Plugs, and Resolder the Connections to the Electronic Board. Use 10W Pen Iron, and Rosin Core Solder.

 

Basicly at that point, it either works, OK, or it Don't !!!

 

If you have not done that proceedure, its highly reccomended, by Many.

 

------------------------

 

Another item to check. Follow the cable from the Ignition Switch, to a pull apart Plug.

Open plug, and Take a resistance reading Thru-- the " ON-OFF" contacts of the Switch. Use Color Code to identify the correct pins.

 

Also Use CRC 2-26 on that Plug.

 

Double check your Ignition Fuse, if you have not yet Replace your Fuse Block, with and ATM type Block.

---- OR--- REplace the 15 Amp Ignition fuse with an IN-LINE fuse holder for now.

 

Being as it runs, then does not, then does again, I would be highly suspect of that Ignition Fuse.

 

I guess the Next thing I would be looking for is a bad Ground connection. ( Then Main grounding stud locagted Under the Upper Left Fairing Section. ) Its hard to get to.

 

Might be loosing the main ground to the TCI. See diagram for the larger of the two plugs of the TCI, one of them is Black goes to ground. Check that black wire, make sure its got a good ground.

 

Have you ever opened up your Main 40 Amp fuse?? Might be a loose Screw there that holds the element in place, not likly, but possible.

 

I think you on a Witch Hunt here, could be lots of things. ???

 

Maby the TCI internals, as you suspect, But, I 'm not ready to go there yet. :confused07:

Edited June 3, 2009 by GeorgeS

[muffinman]

Randy get a small cotter pin and bypass the kill switch and ride it.I would suspect the kill switch before the TCI.

Jeff

[MikesBike]

As I was going to suggest bypassing the kill switch and any other limit switch in circuit one at a time to eliminate them as a possibility. As far as the diaphragms, how do the old ones look and would you be interested in getting rid of them? I've drug home an '84 venture with minor problems. Now if I could sell this junky old Goldwing I could pay for the venture...

Mike

[GeorgeS]

Did you check out the Plug in the cable going to the " Pick up Coils " ????

 

That plug has caused a few problem for folks. !!

[Gearhead]

 

The plug is behind the LH side cover, behind where your left calf sits when riding, near the stator - regulator connector. Or, on a similar track, my Virago once had problems with those wires right where they come out of the LH engine case cover.

 

Jeremy

[Venturous Randy]

I may have found my problem. I again took my headlight out and checked several connections, such at the ones coming from the kill switch, tightened the pinch points, sprayed contact cleaner and put it all back together. I had cleaned the side stand switch a year or so ago and put a good boot on it. But I started checking across the terminals and was getting all kinds of resistance readings. I could put the side stand up and down and the readings were every where. So, I took the middle gear cover and foot peg off to get to it. I put it in a vice so I could more consistantly put the probes on and still got irratic readings. I sprayed a bunch of contact cleaner in it and moved it on and off a bunch of times and all my resistance readings were very good. I am hoping that flipping the kill switch off and on and it restarting may have been more of an electrical surge thru the sidestand switch that made contact. I can dream, can't I?

So, I hurriedly put everything back together and just as I started it, and it fired instantly, it came a downpour. Now, it is either fixed or I lucked out and did not get caught in a heavy rain after it quit again.

I now have something to look forward to tomorrow when I get home and I will get to try out my new diaphragms.

Wish me luck as this has been very depressing.

RandyA

[Venturous Randy]

I got it running great. In fact, I believe it is running stronger than I can ever remember and I have put 99,000 miles on it. In 1st gear as it starts to pass about 3,000 rpm's it begins to pull real hard and the tach wraps up to 8,000 rpm's real quick.

It ended up being the side stand switch had a lot of resistance and after I cleaned it, no resistance.

I also helped that I cleaned a bunch of terminals, replaced the spark plugs, checked the pressure sensor and above all, I put in new diaphragms.

It was so good to be able to take a smooth ride, but I caught myself looking for a place to CRANK IT ON!!

I really appreciate everyone's suggections and comments.

RandyA

[GeorgeS]

So, you found the culprit, and in the process you " Accidentally" fixed a few more !!