The
If
you have performed much electrical work on your
650 you know by now the prints are hard to read
and have numerous errors in them. The following
data is provided in an attempt to assist you in
overcoming the electrical frustrations you'll
encounter.
Alternator
Mechanical Regulator
This drawing shows the
early model 650 charging system with the
mechanical voltage regulator. It has the seperate
rectifier that converts the AC voltage into DC
voltage.
Alternator
Solid State Regulator
This drawing shows the later model 650 charging
system with the solid state regulator. The AC to
DC rectifier is built into the module.
Alternator
Test Mechanical Regulator
This image gives you specific values you should
see when taking measurements on 650's with
separate mechanical voltage regulators and
rectifiers to determine why your charging system
is not producing voltage. Pay particular
attention to the meter settings noted. Refer to
your service manual for locations of devices.
Alternator
Test Solid State Regulator
This image gives you specific values you should
see when taking measurements on 650's with
electronic voltage regulator systems to determine
why your charging system is not producing
voltage. Pay particular attention to the meter
settings noted. Refer to your service manual for
locations of the module.
Digital
Volt Meter Set Up For Amps & Ohm Readings
This image shows a typical digital meter readout
and how to connect yours to a diode array
(rectifier section), to the rotor and stator
coils, and the type of readings you should see.
Note that some meters do not show the decimal
point on DIODE settings and that values around 4
to 7 are acceptable. Also, always check for true
zero on your meter when reading resistance. Refer
to you meter's manual to determine what infinity
looks like on your readout.
Service
Manual Flasher Wiring Error Correction
A lot of the service manuals have errors in the
wiring diagrams. It's hard enough to troubleshoot
without being led down the wrong path. This image
shows the corrected color coding and connection
for the flasher wiring on 1977 and up 650's which
is wrong in the manuals.
1974-75
Starter, Alternator, & Ignition Circuitry
This image shows the starter circuitry for a 1975
XS650 but is typical of other early 650's
hopefully drawn in a manner that is easier to
read and understand. It includes the safety
relay, alternator circuitry as well as ignition
system. It also answers the infamous question
"What is that small silver thingie under the
tank by the flasher?" :-) The polarity diode
that tests the brake lining alarm indicator each
time you start the bike.
Testing
for Loose Connections
This image gives you some insight as to how
voltage drops can effect your 650's electrical
system. It shows how to take measurements across
connections to see if a loose connection is
present. The circuits are coded in blue,
identified on the left side of the page and you
can refer to your electrical wiring print to
obtain the actual wire colors. Placing you meter
across the components as noted (such as the
ignition switch) and measuring any voltage
present while under load will tell you it's
condition. Note that loose connections deprive
coils, ignition circuitry of voltage and can
result in poor performance. Left uncorrected,
loose connections can melt electrical plugs or
connections resulting in major repairs. This is a
common problem with wiring systems.
Clutch
Inspection/Adjustment
There is nothing more aggravating than a clutch
that won't release properly. What's worse is to
be out in the middle of no where and have a cable
break. Periodic inspection and preventative
maintenance can prevent this. I personally am
pleased with the operation of my 650's clutch
release system. This page outlines what I do
religiously to keep it that way. It makes
reference to this picture. Clutch
Exploded View
Surprise
Information
One never knows what might be placed here.
Technical pictures, troubleshooting secrets, food
for thought articles. Keep checking back
regularly, you might be "Surprised' at what
you find.
Well, that's it. I really
would appreciate any feed back you would care to
offer, good or bad, in regards to additional info
needed or errors in the information provided. So
please contact me.
God Bless You & Yours & Our USA
Ken Maxwell
650 Society Member #5077
1975 XS650B, 1974 TX650A, 1974 TX650A
E-mail
Ken
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