XSPen
XS400 New Member
Hey guys, new to the forum!
Just wanted to thank everyone, this has been a wealth of knowledge this past week while trying to get my XS up and running.
My left side pickup coil blew out and I was getting massive voltage spikes in the circuit (while cranking) but for the life of me could not figure out why. i rewired all grounds and primary connections, put in a new fuse box, checked and resoldered every joint and resistor on the TCI, did all the basic peripheral checks, and traced shorts to no end, until I found this little DIODE buried in the harness beneath the seat.
It had given out and was Backfeeding current from the headlight circuit, into the ignition (via the handlebar start/stop controls) and down into the coil through the TCI.
Anyway, I needed my bike running and didn't want to buy a pickup coil, so I made one.
I used a pair of vice grips and a small hammer to separate the magnet from the coil, and dremelled the plastic cover in half to retrieve the bobbin.
It took me half an hour to get the (lightly) epoxied wire off of it with a metal pic. I didn't have any 42AWG wire sitting around, but I did have an old forklift voltage regulator with similar guage windings.
After carefully unwinding the regulator's coil onto a screwdriver, I used the wire to rewrap my bobbin, which took about an hour altogether.
Once I finished, I epoxied the bobbin directly to the magnet, wrapped with electrical tape, more epoxy, soldered on a couple of leads and presto! It's functioning beautifully.
So, if you're in a bind and have some spare parts around, it is doable lol
Just wanted to thank everyone, this has been a wealth of knowledge this past week while trying to get my XS up and running.
My left side pickup coil blew out and I was getting massive voltage spikes in the circuit (while cranking) but for the life of me could not figure out why. i rewired all grounds and primary connections, put in a new fuse box, checked and resoldered every joint and resistor on the TCI, did all the basic peripheral checks, and traced shorts to no end, until I found this little DIODE buried in the harness beneath the seat.
It had given out and was Backfeeding current from the headlight circuit, into the ignition (via the handlebar start/stop controls) and down into the coil through the TCI.
Anyway, I needed my bike running and didn't want to buy a pickup coil, so I made one.
I used a pair of vice grips and a small hammer to separate the magnet from the coil, and dremelled the plastic cover in half to retrieve the bobbin.
It took me half an hour to get the (lightly) epoxied wire off of it with a metal pic. I didn't have any 42AWG wire sitting around, but I did have an old forklift voltage regulator with similar guage windings.
After carefully unwinding the regulator's coil onto a screwdriver, I used the wire to rewrap my bobbin, which took about an hour altogether.
Once I finished, I epoxied the bobbin directly to the magnet, wrapped with electrical tape, more epoxy, soldered on a couple of leads and presto! It's functioning beautifully.
So, if you're in a bind and have some spare parts around, it is doable lol
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