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From: Patti on 15 Feb 2010 10:25
The last time I worked on my 1985 XL600R was about 5 years ago - at that
time it would start with a lot of effort, but wouldn't stay running
reliably. Someone on this forum suggested going through the Clymer or
Haynes manuals' trouble-shooting section, and I could have SWORN I did
and that the last thing to check in the trouble-shooting tree (assuming
good spark, fuel, etc.) was the kill switch.

I just sold it to a co-worker who wants to get it running, and he says
he measured the kill switch as being shorted irrespective of the
position it was in. (so to me that means the kill switch must have been
the culprit - how often do 2 things go wrong at the same time?)

Meanwhile, neither the Clymer or Haynes manuals even *mention* the kill
switch, nor show it on the wiring diagrams. (Did I dream the
kill-switch thing in the trouble-shooting tree?) He finally found a
schematic online that shows the kill switch, and it should be *open* to
run, so he just cut the wires.

When I was trouble-shooting 5 years ago, I had the head done (new valve
seals, new cam, re-seating the valves, new timing chain), replaced the
pulser, CDI unit, and rebuilt the carbs - but danged if the thing still
won't run reliably. The guy I sold it to checked the rectifier and
tells me it's not got continuity as it should (according to manual) -
but that's the *one* part they don't make any more. It does have a
spark, so is the rectifier really necessary? I didn't disassemble the
bottom-end when I did the head/pulser, so the timing should still be
correct.

Can anyone help please? It used to run really sweet and was easy to
start until this problem developed. I see the factory manuals are $50
on ebay for that model year. I may have seen the kill-switch in the
trouble-shooting section of one of those then lost it (???)

Thanks!
PattiM
From: ` on 15 Feb 2010 11:36
On Feb 15, 7:25 am, Patti <mic...(a)earthlink.net> wrote:

> Can anyone help please?

You're wasting your time posting to this troll-infested NG.

Take your dirtbike questions to a dirtbike NG.
From: Rob Kleinschmidt on 16 Feb 2010 22:54
On Feb 15, 7:25 am, Patti <mic...(a)earthlink.net> wrote:
> The last time I worked on my 1985 XL600R was about 5 years ago - at that
> time it would start with a lot of effort, but wouldn't stay running
> reliably.  Someone on this forum suggested going through the Clymer or
> Haynes manuals' trouble-shooting section, and I could have SWORN I did
> and that the last thing to check in the trouble-shooting tree (assuming
> good spark, fuel, etc.) was the kill switch.
>
> I just sold it to a co-worker who wants to get it running, and he says
> he measured the kill switch as being shorted irrespective of the
> position it was in.  (so to me that means the kill switch must have been
> the culprit - how often do 2 things go wrong at the same time?)
>
> Meanwhile, neither the Clymer or Haynes manuals even *mention* the kill
> switch, nor show it on the wiring diagrams.  (Did I dream the
> kill-switch thing in the trouble-shooting tree?)   He finally found a
> schematic online that shows the kill switch, and it should be *open* to
> run, so he just cut the wires.
>
> When I was trouble-shooting 5 years ago, I had the head done (new valve
> seals, new cam, re-seating the valves, new timing chain), replaced the
> pulser, CDI unit, and rebuilt the carbs - but danged if the thing still
> won't run reliably.  The guy I sold it to checked the rectifier and
> tells me it's not got continuity as it should (according to manual) -
> but that's the *one* part they don't make any more.  It does have a
> spark, so is the rectifier really necessary?  I didn't disassemble the
> bottom-end when I did the head/pulser, so the timing should still be
> correct.
>
> Can anyone help please?  It used to run really sweet and was easy to
> start until this problem developed.  I see the factory manuals are $50
> on ebay for that model year.  I may have seen the kill-switch in the
> trouble-shooting section of one of those then lost it (???)

Hi Patti

This site should be helpful.

http://www.electrosport.com/technical-resources/diagnosis-center.php

Seems like you might be able to find an aftermarket
regulator/rectifier. This part is for the charging circuit
anyway. It shouldn't affect the bike's ability to start
if the battery's already go a full charge.

Not really clear if the guy who bought the bike knows
what he's doing.

On mine, the kill switch makes and breaks a circuit.
Not sure what he means "shorted out". Try to get a wiring
diagram for the bike (might be one in Haynes) and see
where the kill switch fits into the picture.

My suggestion would be to fully charge the battery,
empty the tank, refill with new gas and then try
starting. If it doesn't start, check to see if you have
a spark at the plugs and if so, clean the carbs.
If no spark, is there 12 volts at the coil ?

The electrex site always used to have really good
troubleshooting instructions.

Worry about the rectifier and charging system after
the engine will fire.
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