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I have a 83 xs 650 cafe that I am finishing up a complete custom wiring harness on. I have not seen this current motor run, but the original speedo showed 9600 miles. I am experiencing no spark after what i feel is a properly wired motor. I have compared to tons of diagrams online and it appears to be correct. I am thinking i have a bad cdi unit. I understand there is no way to test the CDI....correct? I am prepared to bite off a aftermarket electronic ignition. Boyer or Pamco? Which is easier to install?Any thoughts or comments are appreciated. Thanks
The 83' model has a Ralph Nader safety feature that compels you to be sure that the kick stand is up before starting. This feature, designed to keep you form hurting yourself, uses a switch on the kick stand and a relay under the left side cover to disable the ignition system if the kickstand is down. A real PITA. So, locate the relay in question and remove it. There is no wiring bypass required. Just pull that relay to see if that is the problem.
In your case, with a custom wiring job, it's possible that you somehow wired up the disable feature so it is permanent. Check the stock wiring diagram to see what is involved. The connection from the side stand relay to the TCI should just be left disconnected.
Note: The XS650 does not have a CDI (Capacitor Discharge Ignition) system . It has a TCI (Transistor Controlled Ignition) system.
Did you check the pick-up coils for continuity? There are two in the same component. You may also jumper the two wire plug that goes to the sidestand. Also, if you have a nuetral indication, the sidestand is not likely a problem unless it's wired where it shouldn't be.
Pete thanks for the info ....yeah it seems like everything in a little black box I call a Cdi. I realize the 2 are different. It's kinda like calling everything you blow your nose with a Kleenex...lol. I will definately check these other wiring matters that could be causing issues. I realize you may be a bit bias on your info as to what product to use, but I appreciate you bringing these other possible issues to my attention. You may know and I bet you do,in you honest opinion will the pamco set up when wired "properly" solve the issues I am having? Upgrading my ignition for reliability has always been a thought anyhow. this issue may force me to do so.
Jetmech thank you also, I will check these things to. I have a tendancy .....like many to overlook the simple things and assume the worse? I will run a few continuity tests on my pick up coils and check my main coil as well. Thanks again guys
Pamco of course will require you to buy the mechanical advance parts, which can get pricey. People hold onto their advance unit as it is often out of stock at MikesXS. eBay is often your best bet for that.
I've run both Boyer and Pamco.
I used a Boyer on my first XS650 rebuild as it was the only electronic ignition available at the time for the XS650 and I got it on a good deal 2nd hand. Ran perfectly for me for a couple seasons from the first start.
Then last winter I built a new rephased motor, and needed a different ignition so I got the mechanical advance bits and installed a Pamco.
Works just fine too. I have the 'big green monster' coils - bought the Pamco from MikesXS. I find some comfort in not having an electronic box sitting there ready to fail at any moment, and the magnetic hall sensors replacing the points are pretty bomb proof.
Looks like the all-in Pamco kit with advance mechanism and everything is $250, while the Boyer is $300. I'd save the $50 and go with the Pamco.
Went with the pamco. Easy install and she cranked right up. TCI boxes are shit! I think that's why my motor has very little miles on it....it fried and sat in a shed for years. Thanks for the insight guys!
Pete if I had a little Icon with a guy bowing down I would place it here!! I am a believer and have a buddy with the same issues. I am your new salesman. ;D
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